可撓性膠體磨料在不鏽鋼放電孔洞的拋光研究

本研究是利用可撓性膠體磨料配合自製的螺旋流道治具，透過螺桿輸送膠體磨料進行對放電孔洞的研拋加工，但目前螺旋流道機構在研拋時仍有許多缺點，如治具定位不良、尋邊不易、清理費時、研拋不均勻等原因。因此本研究則自行設計治具，並改善上述之問題，進而獲得更有效率的加工及一致性的表面粗糙度，並使用線切割機製作出不鏽鋼管的內孔放電面，作為實驗用之試片，且將自製的治具架設至CNC綜合加工機上，利用螺桿上的螺旋流道探討可撓性膠體磨料對不鏽鋼的放電孔洞之影響。實驗中，先選定一組固定的加工參數，並改變其中單一個參數，探討不同參數對表面粗糙度及材料移除率的影響，再利用田口實驗法尋找出最佳化參數之組合，並觀察加工後試片表面粗糙度之改善，與各加工因子對於研拋效能之影響，經田口法實驗結果，其中膠體、磨料號數、主軸轉速的影響較為顯著，經由變異分析(ANOVA)計算，得知膠體、磨料號數、主軸轉速在本實驗中的貢獻度最高，當加工時間至15分鐘後，表面粗糙度可由Ra0.65μm降至Ra0.09μm，其改善率可達86%，因此，證實膠體磨料對放電孔洞具有優異的研拋效能。

關鍵字

高分子膠體；螺旋研磨法；田口實驗法；表面粗糙度；高效率

並列摘要

This research is mainly to probe into the polishing effect of flexible Gel Abrasive Machining with Helical Passageways (GAMHP) through adjusting screw threads in Electrical Discharge Machining (EDM) hole of Stainless Steel and utilizing flexible gel and abrasive material with hand-made helical passageways fixture. In order to improve the defects such as difficulties in positioning fixture and edge-finding, the time-consuming in cleaning and uneven polishing resulted in the previous research, and to achieve greater effective processing results and diminishes identical surface roughness, the researcher uses the helical passageways within screws to study the effects of flexible gel and abrasive material on the EDM hole of Stainless Steel. The Wire Electrical Discharge Machining is used to produce stainless steel tube, which functions as the work-piece of this experiment. The modified fixture is set onto computer numerical control (CNC) machine. In this study, a set of fixed processing factors are chosen and during the experiment, these factors are adapted in order to find the optimal factor combination. Taguchi Method is applied to search the optimal factor combination and with the combinations, the researcher is able to observe the impact on the material removal rates, surface roughness of the work-piece, and the polishing effects. Through the calculation of Analysis-of-Variance (ANOVA), factors such as flexible gel, abrasive mesh and Z axis turns out to be the most significant in contributing to the polishing effect. The surface roughness can be reduced from Ra 0.65 m to Ra 0.09 m--15minutes. The surface roughness can be improved by 86 %. Therefore, the flexible gel and abrasive materials are proved to have excellent effect on polishing the EDM hole of stainless steel tube.