研究生: |
邱泓智 Hung-Chih Chu |
---|---|
論文名稱: |
以球擠光與球拋光製程作壓鑄用模具鋼之表面精加工研究 Surface Finish of the Die Casting Mold Tool Steel Using Ball Burnishing and Spherical Polishing Processes |
指導教授: |
修芳仲
Fang-Jung Shiou |
口試委員: |
陳炤彰
Chao-Chang Chen 許東亞 Dong-Yao Sheu 巴白山 Pai-Shan Pa |
學位類別: |
碩士 Master |
系所名稱: |
工程學院 - 機械工程系 Department of Mechanical Engineering |
論文出版年: | 2006 |
畢業學年度: | 94 |
語文別: | 中文 |
論文頁數: | 148 |
中文關鍵詞: | 8407-MS壓鑄用模具鋼 、球擠光 、球拋光 、田口式實驗計劃法 、最佳拋光參數 |
外文關鍵詞: | 8407-MS die casting mold tool steel, ball burnishing process, spherical polishing process, Taguchi’s matrix experiments, optimal spherical polishing parameters |
相關次數: | 點閱:562 下載:1 |
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本論文乃針對8407-MS壓鑄用模具鋼進行自動化的擠光加工與拋光加工之研究,以田口實驗計劃法於平面試件上進行直交表實驗,分別找出擠光加工與拋光加工之最佳參數,並將最佳加工參數應用於逆向工程建構出之自由曲面載具,本研究先於試件上進行粗精銑外形與研磨、再由最佳參數依序進行擠光加工與拋光加工製程,以得知最佳加工參數應用於3D自由曲面上對表面粗糙度之改善情況。
研究中分別採用L9與L18的直交表進行擠光與拋光加工實驗,且由變異數分析找出影響最大的因子,經全因子實驗與驗證實驗來取得最佳的參數組合。實驗後可得知擠光加工最佳參數組合為擠光力250N、進給200mm/min、間距20μm、擠光路徑與研磨刀痕正交。而拋光加工最佳參數組合為磨料採用氧化鋁(WA)磨料、拋光路徑與擠光塑性變形之紋路平行,拋光球頭轉速為22000rpm、進給為80mm/min、間距為60μm、Z軸進深為40μm。
應用此最佳參數於平面試件時,擠光加工後表面粗糙度可達Ra為0.064μm、Rmax為0.773μm;拋光加工後可達Ra為0.0166μm、Rmax為0.194μm。而應用此最佳參數於自由曲面載具時,擠光加工後可達Ra為0.192μm、Rmax為1.598μm,拋光加工後Ra可達0.036μm、Rmax為0.378μm。
The objective of this research is to improve the surface roughness of the 8407-MS die casting mold tool steel using the ball grinding, ball burnishing and spherical polishing surface finish processes on a machining center. The optimal plane surface ball burnishing and spherical polishing parameters have been determined after conducting the Taguchi’s L9 and L18 matrix experiments, analysis of variation (ANOVA), and the full factorial experiments, respectively. The optimal plane ball burnishing parameters for the used tool steel were the combination of the burnishing force of 250N, the burnishing speed of 200mm/min, the feed of 20μm, and the burnishing path orthogonal to the grinding direction. The optimal plane spherical polishing parameters for the used tool steel were the combination of the WA abrasives of Al2O3 with grid no. 6000, the feed of 80 mm/min., stepover distance of 60μm, depth of penetration of 40μm, the grinding speed of 22,000 rpm, and the polishing path parallel to the burnishing direction. The surface roughness of the test specimens could be improved from about Ra 0.521μm to Ra 0.064μm (Rmax 0.773μm) in average using the optimal plane surface ball burnishing parameters. The surface roughness of the burnished specimen can be further improved to Ra 0.017μm (Rmax 0.194μm) using the optimal plane surface spherical polishing process with the determined optimal plane surface polishing parameters. Applying the optimal plane surface ball grinding, ball burnishing and spherical polishing parameters sequentially to a fine milled freeform surface carrier of an Enter key for the 8407-MS die casting mold tool steel, the surface roughness of Ra 0.036μm (Rmax 0.378μm) on the freeform surface is obtainable.
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