本研究旨在探討自製拋光工具對STAVAX模具鋼於機械手臂進行即時定力拋光研究，以即時定力控制系統配合防過載治具之行程，限制拋光力，減少力量起伏之問題，達成表面均勻拋光效果；本研究以田口計畫法探討自製拋光橡膠體對STAVAX模具鋼建議拋光參數，並應用於試件平面及具有凹凸輪廓之自由曲面，依試件外型選用不同拋光工具及拋光道次，為實現一種拋光工具智慧選用方法。
本研究為透過計算力量目標值與彈簧K值間位移關係式，將其計算出結果設定為滑槽行程，進行防過載裝置拋光治具之研製；從驗證實驗可知，藉由滑槽行程之限制，能有效限制最大拋光力量。
本研究採用之定力控制為簡易PID控制，由壓深實驗得到初步之KP值，再由實驗進行參數調整，可得到各種橡膠拋光體其控制參數為：直徑40 mm橡膠拋光參數為KP 0.025、KI 0.015、KD 0；直徑20 mm橡膠拋光柱KP 0.02、KI 0.005、KD 0；直徑20 mm橡膠拋光球KP 0.1、KI 0、KD 0。
本研究參考先期研究最佳球擠光參數，以潤滑油為變數進行測試，得到殼牌68號滑道油對表面粗糙度改善較高，試件平面之表面粗糙度可降至R_a 0.036 μm。以田口計劃法求出橡膠拋光體之最佳拋光參數，應用於平面拋光之直徑40 mm橡膠拋光柱建議參數為：粒徑0.3 μm、轉速 5600 rev/min、進給率0.1 mm/min、拋光力6 N；應用於自由曲面拋光為直徑20 mm橡膠拋光柱、球。將最佳拋光參數應用於平面及自由曲面，拋光後試件平面表面粗糙度由R_a 0.036 μm降至R_a 0.02 μm；自由曲面經拋光柱、多道次球拋光後表面粗糙度由R_a 0.185 μm降至R_a 0.04 μm、R_a 0.02 μm。
與先期研究相比，平面於擠光後表面粗糙度改善R_a 0.03 μm，平面及自由曲面於拋光後表面粗糙度分別改善R_a 0.01 μm、R_a 0.02 μm，證實改良治具及使用即時定力控制能夠有效改善表面粗糙度。

The aim of this study is to investigate the effects of a lab-made polishing tools on the real-time force-controlled polishing of STAVAX mold steel using a six-axis industrial robot. A real-time force control system with a modified overload prevention fixture has been developed to restrict the polishing force and to improve the problem of force fluctuations, resulting in a uniform polishing effect. The Taguchi method was applied to investigate the recommended polishing parameters for the lab-made polishing tools for the STAVAX mold steel. Different polishing tools and polishing sequences were selected according to the shape of the specimen, to achieve an intelligent selection method.
An overload prevention fixture has been designed and fabricated in this study. Based on the displacement relationship between the force target value and the spring (K value), the suitable stroke of the sliding slot was calculated. From the experimental results, it can be shown that the maximum polishing force can be effectively limited by setting the stroke of the sliding slot.
The PID controller has been adopted in this work for constant force polishing. The preliminary KP value was obtained from the pressure depth experiment, and the parameters were adjusted through the polishing experiment. The parameters for the cylindrical polishing tool with a diameter of 40 mm are KP 0.025, KI 0.015, KD 0; for the cylindrical polishing tools with a diameter of 20 mm, the parameters are KP 0.02, KI 0.005, KD 0; for the spherical polishing tools with a diameter of 20 mm, the parameters are KP 0.1, KI 0, KD 0.
Referring to previous studies on the optimal ball burnishing parameters, the lubrication oil was used as a variable for testing. The Shell hydraulic oil of No. 68 was found to have a higher improvement on surface roughness, reducing the surface roughness of the specimen with plane surface from Ra 0.066 μm to Ra 0.036 μm. The Taguchi method was applied to determine the optimal polishing parameters for the polishing tool. For the flat plane polishing using a cylindrical polishing tool with the diameter of 40 mm, the recommended parameters were the particle size of 0.3 μm, rotation speed of 5600 rev/min, feed rate of 0.1 mm/min, and polishing force of 6 N.
The optimal polishing parameters have been applied to both the flat and freeform surfaces. The surface roughness of the plane specimen was improved from Ra 0.036 μm to Ra 0.02 μm after polishing. The surface roughness of the freeform surface area has also been improved. After the surface finishing using the cylindrical polishing tool and multiple-pass ball polishing, the surface roughness of the specimen was reduced from Ra 0.185 μm to Ra 0.04 μm and Ra 0.02 μm, respectively. Compared with the previous studies, the surface roughness of the flat specimen was improved by Ra 0.03 μm after ball burnishing, and the surface roughness of the flat and freeform surfaces was improved by Ra 0.01 μm and Ra 0.02 μm after polishing. According to the experimental results, it can be confirmed that the surface roughness of the test specimen can be effectively improved by modifying the fixtures and using real-time force control.

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