單件式的大型框形板件為機械產業所需之機構元件。由於製程中材料的移除比例很高，成品的結構強度與平面度誤差都有很大的挑戰，稱之為體積塊除料 (BMR，bulk material removal)。本研究探討半導體測試設備使用之大型鋁製框架製造程序，秉持循環式品管方法(PDCA)之精神，以製造成本為管理目標，共執行8組實體切削實驗，促使製造成本持續地改善，建立標準作業規範。

本研究討論不同體積塊除料方式的製造成本效應，包括：加工機具 (切削加工機、水刀加工機)與NC程式軟體 (UG/NX與SolidCAM)。研究案例的材料移除率達79.73%，產品除了符合輪廓尺寸要求外，框架的平面度誤差必須控制在0.05 mm之內。實驗結果顯示：水刀加工雖有最短的佔機時間，與習用工法相較有53.80%的降幅；但是總製造成本增加29.87%，而且電力碳排量遠高於習用的銑削程序。使用中心出水銑削方法，製造成本略為增加，但是佔機時間有可觀的降幅50.31%。改變除料工法，採用綜合插銑與等高軌跡銑削的NC加工程序，可以充分發揮端銑刀具的特色，雖然總製造成本的改善僅1.28%，佔機時間可以降低45.98%。本研究提出半導體測試產業用大型鋁製框架製作之建議作業規範，可做為製程規劃與生產排程之參考。

A large-scale frame panel in one-piece is one of essential structure component used in the mechanical industry. Because the proportion of material removal is high during the manufacturing process, the products have great challenges such as the structural strength and the flatness error of the frame plate, which process is called bulk material removal (BMR). This study investigates the process of a large-scale alumina frame used in the semiconductor testing device. According to the spirit of circular quality control method (PDCA), taking manufacturing cost as the management goal, a total of 8 sets of physical cutting experiments were carried out to improve the manufacturing cost continuously, and established standard operating procedures.

The study investigates effects of the manufacturing cost by different BMR methods, included cutting machines (machining centers, water jet machines) and NC programming software (UG/NX and SolidCAM). The material removal rate of the case studied is 79.73%. In addition to satisfying the requirements of product’s contour, the flatness error of the frame must be controlled within 0.05 mm. Experimental results show that although waterjet machining has the shortest operating time, compared with the conventional milling method, the operating time can be reduced by 53.08%; the manufacturing cost increases by 29.87%. In addition, its electricity carbon emission is more heavy than the conventional milling process. Using the center coolant milling method, the manufacturing cost increases slightly, but the operating time has a considerable decrease of 50.31%. Changing the BMR process by the method integrating the plunge milling and the trochoidal milling can fulfil the cutting characteristics of an end mill. In spite of the total manufacturing cost is only improved by 1.28%, the machine time can be reduced by 45.98%. The experimental data provide useful references for the process planning and production scheduling of making a large-scale aluminum frame used in the semiconductor testing industry.

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