運用田口方法於決定線性滑軌鑽孔製程參數最佳化之研究

Using Taguchi Method to Determine the Optimal Parameters for Rail Drilling Process

廖睿鴻(Ruei-Hong Liao)

指導教授 ： 張俊郎

國立虎尾科技大學/管理學院/工業管理系工業工程與管理碩士班/碩士(2017年)

摘要

為因應線性滑軌生產技術漸趨成熟，市場上競爭也日益激烈，如何有效控管及降低生產加工成本，是在紅海市場中確保公司獲利及產品競爭力之首要課題。在面對先進的高速切削加工生產技術時，對於刀具加工成本與刀具壽命的要求日趨重要。
有鑑於目前業界所使用經驗法則來調配加工參數，程序繁複費時且測試成本高昂，因此，本研究利用田口方法（Taguchi method）來決定ψ7鑽頭的最佳鑽孔加工參數設定(以H公司為例)。運用特性要因圖篩選出七項控制要因；包含刀具含鈷量(A)、刀具刃角(B)、刀具鍍層(C)、刀具偏擺(D)、主軸轉速(E)、每刃進給(F)、半合成切削液濃度(G)等參數因子作為實驗的控制因子，以主軸在加工當下之電流負載值為刀具切削性能指標，求得最多加工孔數之製程參數組合供生產線參考使用。
本研究針對七項控制要因進行測試分析，以直交表L18(21x37)的方式整理出各個測試條件之配置，並以變異數分析(ANOVA)對測試結果進行最佳化的演算，訂定出最佳參數組合(A1、B2、C1、D2、E2、F1、G2)做為二次實驗之驗證。驗證結果顯示，以田口方法所得製程參數最佳水準組合，能夠有效提升24%以上的刀具加工壽命。

關鍵字

線性滑軌 ； 高速切削 ； 刀具壽命 ； 田口方法 ； 製程參數

並列摘要

In response to the increasingly mature production technology for linear slide rails, competition in the market is also intensifying. Therefore, how to effectively control and reduce processing costs in production is a top issue that companies have to tackle successfully in order to ensure their profitability and the competitiveness of their products in a red ocean market. In the face of advanced high speed cutting technologies for processing production, processing costs with cutters and the requirements for cutter lifespans are becoming increasingly important.
Given that the industry’s current rule of thumb based approach to processing parameter adjustment and assignment, it involves complex and time-consuming procedures and high testing costs, this research uses Taguchi method as an alternative approach to determining optimal parameter settings for the drilling process (with Company H as an example for demonstration). Based on a cause-and-effect diagram, seven key control factorswere selected, which included these parametric factors: cobalt (Co) content in the cutter (A), cutting edge angle of the cutter (B), coating on the cutter(C), run-out of the cutter(D), rotational speed of the main axis(E), feed per tooth (F) and concentration of the semi-synthetic cutting fluid(G)to be used as the control factors for experimentation in this research. The current load on the main axis at the time of processing was defined as the cutting performance indicator for the cutter in order to obtain the optimal combination of process parameters that produced maximum processing holes to be provided as a reference for production lines.
In this research, testing and analyses were run on the seven key control factors. The Latin square L18 (21x37) was used for determining the configuration of each testing condition. The testing results underwent an ANOVA for optimization calculation. The optimal combinationof parameters (A1, B2, C1, D2, E2, F1 and G2) was thus established for verification in the confirmation experiment. The verification results showed the combination of process parameters with the optimal level identified with Taguchi method could effectively increase the cutter lifespan by over 24%.

並列關鍵字

Linear Slide Rail ； High Speed Cutting ； Cutter Lifespan ； Taguchi Method ； Process Parameter

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