本研究旨在研發一新型內建荷重計球擠光工具，於CNC車床上進行SUS420J2塑膠模具鋼表面精加工之研究，其目的為探討擠光加工後之表面粗糙度、真圓度以及表面硬度改善情況，本研究以田口實驗法對SUS420J2塑膠模具鋼探討圓柱形試件滾動式最佳化參數，再將其參數應用於具有錐度之試件上。
本研究之最佳滾動式擠光加工參數係以田口實驗L18直交表進行，經由變異數分析，探討滾動式擠光加工參數對於表面粗糙度、真圓度及表面硬度之影響，再進行驗證實驗以取得最佳化滾動式擠光參數。由實驗結果得知最佳化滾動式擠光加工參數為：擠光球材質-碳化鎢、擠光力-650N、進給率-0.05mm/rev、速度-25m/min、潤滑劑-切削劑(1：20)及擠光次數-3次。應用最佳化滾動式擠光加工參數於SUS420J2塑膠模具鋼之圓柱形試件，表面粗糙度可由Ra1.1μm改善至Ra0.02μm(Rmax0.202μm)；真圓度可由2.150μm改善至1.235μm；表面硬度可由51HRc改善至53.8HRc。以最佳化滾動式擠光參數應用於不同錐度之試件，其平均粗糙度介於Ra0.04~0.06μm (Rmax0.33~0.63μm)之間。

The objective of this research is to develop a new ball-burnishing tool embedded with a load cell integrated with a CNC lathe, to improve the surface roughness, roundness and hardness of the SUS420J2 plastic mold steel. The optimal ball burnish process parameters of the cylindrical part have been determined by conducting the Taguchi’s L18 matrix experiments, the ANOVA analysis, and the verification tests. Based on the experimental results, the optimal combination of the process parameters is as follows: the ball material of WC, the burnishing force of 650 N, the feed rate of 0.05 mm/rev, the velocity of 25 m/min, the lubricant of the cutting fluid (oil/water ratio of 1/20) and the number of pass of 3. The surface roughness of the test specimen could be improved from Ra 1.1 μm to Ra 0.02 μm (Rmax 0.202 μm), the roundness could be improved from 2.150 μm to 1.235 μm and the hardness could be increased from HRc 51 to HRc 53.8 using the optimal process parameters. The influences of the process parameters on the surface roughness, roundness and hardness have also been discussed. Applying the optimal process parameters to a workpiece with different tapers, then the surface roughness could be improved from Ra 1.0 μm to Ra 0.04-0.06 μm on average.

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