積層製造(Additive Manufacture, AM)製程之優勢為用於生產複雜幾何之零件，減少加工程序進而降低生產成本。雖然如此，在雷射燒熔(melting)金屬粉末與固化成相(consolidation)過程中，熱效應產生積層間之非均性與非等向性，因此引起材料表面完整性與尺寸精度的變異。本研究探討之後加工製程(post processing)可用於雷射燒熔金屬構件，並建立以微銑削(micro milling)與刀具幾何互為關聯之切削力模型。模型中分析了進給率與刀尖半徑之關係，產生剪切與犁切之臨界條件與切屑形成之機制。實驗設計中，考慮最小切屑形成之厚度與進給率(5–15 μm/tooth)，用以描述剪切、犁切與黏滯區之切削行為。並操作切削速度(30–80 m/min)，用於調整剪應變率所產生的剪力集中效應。當切削測試進行於選擇性雷射燒熔區(Ti-6Al-4V)、過渡區(Ti-6Al-4V/CP01 Ti)與底材區(CP01 Ti)時，量測切削力、切削溫度、刀具磨耗與刀尖半徑幾何、表面粗糙度與輪廓形貌，討論物理機制並進行統計檢定與分析。實驗結果顯示，在雷射燒熔區裡，提高切削速度可以增加剪切作用，因而降低切削力與切削溫度。於過渡區，降低進給率可以減少切削力。於底材區，進給率與切削速度對切削溫度皆產生影響。當過濾、辨識並移除實驗數據之離群點後，可以建立分析模型，並得切削力之模型精度(~87%)。刀具磨耗與顯微組織，加工表面形貌與切削條件之關聯，皆與常規商用材料進行比對，討論其形成機制並詳加探究其原因。

Additive manufacturing (AM) process has been prevalently used in prototyping and production of parts with complex geometry, for the advantages of shortening manufacturing procedures and thus reducing costs. Nonetheless, while components are produced by laser melting of metallic powders, mechanical performances altered due to the thermal induced effects, which led to inhomogeneous and anisotropic properties. Hence, post machining necessitates its importance for retaining satisfied surface integrity and dimensional accuracy. This study investigates the size effects, when machining of laser melting metallic components, in association with the established cutting force model and experimental work on micro milling. While the model analyzes the relationship between feed rate and tool edge radius, the critical conditions for shearing, ploughing and chip formation mechanism can be suggested and identified. In the design of experiments, the operated feed rates (5–15 μm/tooth) were to correlate with the cutting mechanisms in shearing and ploughing in the stagnation zone. Whereas the controlled cutting speeds (30–80 m/min) were used to explain the stress concentration effects and the associated shear strain rates. When the cutting tests are performed in the laser molten zone (Ti-6Al-4V), fusion zone (Ti-6Al-4V/CP01 Ti) and substrate (CP01 Ti), the objectives of cutting force, cutting temperature, tool wear and edge geometry are recorded and evaluated. Machined surface roughness and profile are statistically analyzed and reported. As a results, increasing cutting speed can reduce cutting forces and cutting temperatures in the laser molten zone. Whereas reducing feed rate can reduce cutting forces in the fusion zone. In the substrate, both the feed rate and cutting speed have significant effects on the cutting temperatures. In the fit analytical models, the accuracy of the cutting force can be obtained with appreciable precision level (R2 ~87%). The underlying mechanisms of the tool wear, machined surface topography and alterations in microstructures which are interacting with the cutting conditions, are all reviewed and discussed in detail.

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