本論文旨在研發一創新型內建荷重計之擠光工具，應用於STAVAX不生銹塑膠模具鋼與PDS5塑膠射出模具用鋼之自動化表面精加工之研究，其主要目的在探討擠光加工後之表面粗糙度改善情形。本研究以田口實驗法對STAVAX模具鋼找出滾動式擠光最佳化參數，再將其參數應用於2.5D曲面與3D自由曲面上，並以最佳化滾動式擠光加工參數為基礎，進行PDS5塑膠射出模具用鋼平面最佳擠光力量調整實驗，找出最佳之滾動式與滑動式擠光加工之正向擠光力，進而應用於陡峭之斜面與2.5D曲面，探討滑動式定力擠光加工與滑動式擠光加工之表面粗糙度改善情形。
本研究之最佳滾動式擠光加工參數以田口實驗L18直交表進行之，且由變異數分析，探討滾動式擠光加工參數對於表面粗糙度之影響，再經由全因子實驗與驗證實驗取得最佳化滾動式擠光參數組合。經實驗結果得知最佳化滾動式擠光加工參數為：潤滑劑-太古油( 1:50 )、擠光球材質-碳化鎢( Co 6% )、擠光力- 850 N、進給速率- 800 mm/min、間距- 60 μm、擠光加工路徑與球銑削方向垂直。應用最佳化滾動式擠光加工參數於STAVAX不生銹塑膠模具鋼平面試件，平均表面粗糙度可達Ra 0.03 μm ( Rmax 0.032 μm )，而應用於2.5D曲面與Enter鍵自由曲面，擠光加工後分別平均表面粗糙度約可達Ra 0.07 μm ( Rmax 1.405 μm )、與Ra 0.02 μm ( Ry 0.532 μm )。
經由PDS5塑膠射出模具用鋼平面擠光力量調整實驗得知，最佳滑動式擠光正向力為470 N，且利用此擠光正向力進行陡峭之斜面滑動式定力擠光加工與滑動式擠光加工之比較，得知以定力擠光加工60°陡峭斜面具有表面粗糙度之改善效果，可將表面粗糙度改善至Ra 0.06 μm ( Rmax 0.59 μm )，較滑動式擠光加工表面粗糙度Ra 0.35 μm ( Rmax 4.56 μm )要佳。

The objective of this research is to develop a load-cell-embedded burnishing tool integrated with a CNC machining center, to improve the surface roughness of the STAVAX plastic mold stainless steel and PDS5 plastic injection mold steel. Either the rolling-contact type or the sliding-contact type was possible for ball burnishing using the developed tool. The optimal plane surface burnishing parameters for the rolling-contact type, have been determined after conducting the Taguchi’s L18 matrix experiments, ANOVA analysis, and full factorial experiments. The optimal plane rolling-contact-type burnishing parameters for the STAVAX plastic mold stainless steel were the combination of the lubricant of water-soluble Oils( 1:50 ) , the ball material of WC ( Co 6% ) , the burnishing force of 850 N , the feed of 800 mm/min ,the stepover of 60 μm , and the burnishing path orthogonal to the ball milling direction. The surface roughness of the test specimens colud be improved from about Ra 0.8~1.3 μm to Ra 0.03 μm ( Rmax 0.032 μm ) in average using the optimal plane surface rolling-contact-type burnishing parameters. Applying the optimal plane surface rolling-contact-type burnishing parameters to a fine milled 2.5 dimensional test carrier and a freeform surface test carrier of Enter key for the STAVAX plastic mold stainless steel, respectively, the surface roughness of Ra 0.07 μm ( Rmax 1.405 μm ) and Ra 0.02 μm ( Ry 0.532 μm ) on the 2.5 dimensional surface and freeform surface, individually, were obtainable.

The characteristic curve of burnishing force vs. surface roughness for the PDS5 plastic injection mold steel using the sliding-contact type burnishing tool ,has been investigated and constructed. The optimal plane surface burnishing force for the PDS5 plastic injection mold steel was about 470 N based on the results of experiments. A force compensation strategy that results in the constant optimal normal force for burnishing an inclined surface or a 2.5 dimensional surface, has also been proposed to improve the surface roughness of the test object in this study. The surface roughness of an face milled inclined surface with a slope of 60 degrees can be improved from Ra 2.50 μm to Ra 0.06 μm ( Rmax 0.59 μm ) using force compensation, whereas the surface roughness was only Ra 0.35 μm (Rmax 4.56 μm) with no force compensation.

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