本論文研究為開發一可安裝於三軸、五軸CNC加工中心機之創新型擠光工具，進行銑切工件之擠光表面精加工處理，並針對QC-10杜拉鋁合金材料以赫茲接觸理論與田口實驗設計法進行表面球擠光製程之最佳參數組合探討，與經此製程加工後之表面粗糙度、輪廓變化討論，最後將其應用於塑膠吹製模具之製作。
擠光工具之設計具備外型輕巧、替換性佳、配備無線壓力感測元件與保護感測器之安全裝置等功能，並使用ANSYS Workbench分析軟體進行應力、應變、位移量、安全係數等分析後確認機構之安全性與可行性後製作成品。
尋找製程最佳參數組合之過程為下：首先以赫茲接觸理論計算出三種不同擠光球材質之塑性變形應力區間，配合田口實驗設計法比較後得平面最佳參數組合：ϕ9.5 mm碳化鎢軸承珠、32號抗磨耗液壓油、擠光力4 N、進給速度1500 mm/min、刀路間距殘留高度0.03 μm，可得平面最佳表面粗糙度Ra從原0.34 μm下降至0.078 μm，且將進給速度提升至3000 mm/min內，可在維持品質之環境下提升加工效率。再以自由曲面試片比較旋轉軸(五軸加工)與定軸(三軸加工)之差異，得旋轉軸可應對自由曲面切面之法向量進行接觸角調整，與定軸加工相較表面粗糙度可再降低3.68%至6.84%；最後以弧面試片比較刀路差異，得過度頻繁旋轉使加工效率下降，但表面粗糙度表現與旋轉次數、刀路規劃較為無關，因此選擇較少旋轉次數之刀路則可使加工效率有效提高。
將此工具與參數組合應用於含凸面、凹面、圓角特徵之塑膠瓶吹塑模具，可使表面粗糙度Ra從原平均0.18 μm下降至0.085 μm，且於凸面降低49.71%、凹面降低57.14%、圓角降低53.81%之粗糙值。表面硬度由平均180.2 HV(0.1)提升至190.1 HV(0.1)。

This research aims to develop an innovative burnishing tool that can be installed either on a three-axis or a five-axis CNC machining center for surface finishing of the milled workpieces. The study focuses on investigating the suitable parameter combination for QC-10 aluminum alloy burnishing based on Hertz’s Contact Theory and Taguchi Method, discussing the surface roughness and contour changes after the burnishing process, and applying to the surface finishing of a plastic blowing-injection mold.
The design of the burnishing tool incorporates some features such as light-weighted, replaceability, and embedded with safety devices to protect the load cell with wireless transmission. Prior to manufacturing the tool, the safety and feasibility studies have been verified by considering the stress, strain, displacement, and safety factors analysis, using the ANSYS Workbench analysis software.
The process of determining the optimal parameter combination is as follows: Firstly, the suitable burnishing force of three different burnishing ball materials is calculated based on their plastic deformation stress range with Hertz’s Contact Theory. Then the optimal parameter combination for the planar surface is determined by the Taguchi’s Method as follows: tungsten carbide bearing ball, No. 32 anti-wearing hydraulic oil, burnishing force of 4 N, feeding rate of 1500 mm/min, and stepover scallop height of 0.03 μm. This combination could result in the best surface roughness for the planar surface, reducing the original Ra value from 0.34 μm to 0.078 μm. According to the experiment result, the feeding rate can be increasing up to 3000 mm/min, to improve the processing efficiency and to maintain the same surface quality.
Furthermore, a comparison of the differences between the surface-normal oriented burnishing (five-axis machining) and the z-axis fixed burnishing (three-axis machining) is experimented on a freeform surface workpiece. The rotating of the five-axis machining allows for adjusting the contact angle consistent with the normal vector of the freeform surface, resulting in a further reduction of surface roughness from 3.68% to 6.84% compared with the three-axis (fixed) machining. Lastly, comparing the tool paths using curved surface workpiece reveals that excessive rotation frequency leads to a decrease in processing efficiency. However, the surface roughness improvement is not significantly affected by the rotation frequency and tool path planning. Therefore, choosing a tool path with fewer rotations can effectively enhance the processing efficiency.
Apply the developed burnishing tool and the optimal parameter combination to the test carrier of a plastic blowing-injection mold with convex, concave, and rounded edge features, the surface roughness (Ra) is reduced from 0.18 μm to 0.085 μm on average. Additionally, the surface roughness values were improved 50.87% on convex surfaces, 57.14% on concave surfaces, and 53.81% on rounded edges, individually. Furthermore, the surface hardness is increased from 180.2 HV (0.1) to 190.1 HV (0.1) on average.

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