金屬多孔輕量結構材料製品之低應力加工製程與模組技術

Low stress machining process and module development for light weight porous structure metal product

陳峻偉(Chen Chun Wei) ； 范智文(Fan Zhi Wen) ； 張振暉(Chang Chen Hui)

《亞東學報》 39期 (2019/12) Pp. 37-42

摘要

航太用金屬材料多為難加工材，如鈦合金、高鎳合金及鋁合金等。其不易使用一般機械加工技術完成，故許多國外航太零組件製造商亦使用電化學對其進行加工。然而，金屬多孔結構材通常利用塗膠堆疊接合方式製成，不易使用電化學加工型式進行材料的移除。有鑑於此，本研究創新構想發展，開發電化學加工效應結合機械研磨方式之電化學機械研磨複合加工技術，解決金屬多孔結構材料難加工問題。本研究工作主要兩項：（1）組合式磨輪電極模組建置，開發具導電且能進行機械研磨之磨輪並進行模組建置。（2）針對各加工參數對成形加工影響性進行探討，匹配達成所需之加工特徵、品質與製程運用特性，並就試驗結果回饋修訂電極模組之功能與應用模式，期望藉由機械研磨輔助提升電化學加工效率。通過實驗針對電化學機械複合加工製程參數對鋁蜂巢芯結構成形加工影響性進行探討，得知在操作電壓16 V、磨輪電極轉速800 RPM、進給速率25 μm/s及電解液流速15 m/s下可獲得同時兼具加工表面及精度之成品。藉由此技術開發可克服蜂巢芯結構等難加工材之窘境，有效降低加工成本、工序以及提升產品良率，除此之外亦可將此技術應用於醫材器械零組件、航太領域之各類零組件加工、渦輪發動機零件以及航太扣件等。

關鍵字

電化學機械研磨複合加工 ； 金屬多孔結構材料

並列摘要

Titanium alloy, Inconel 718 and aluminum alloy are widely used for aerospace materials, but those are difficult to use general machining to Manufacture. Therefore, many aerospace component manufacturers also use electrochemical processing.However, porous structural materials are usually made by gluing and stacking, and it is not easy to use an electrochemical processing type for material removal. In view of this, this research innovative concept development, the development of electrochemical processing effect combined with mechanical grinding method of electrochemical mechanical grinding composite processing technology to solve the difficult problem of metal porous structural materials. The main work of this research is as follows: (1) The combined grinding wheel electrode module is built, and the grinding wheel with electrical conductivity and mechanical grinding can be developed and the module can be built. (2) Investigate the influence of each processing parameter on the forming process, match the required processing characteristics, quality and process application characteristics, and feedback the function and application mode of the revised electrode module on the test results. It is expected to be assisted by mechanical grinding. Improve electrochemical processing efficiency.

並列關鍵字

Electrochemical grinding machining ； Metal porous structure

參考文獻

劉文海，「超輕多孔金屬材料之特性與應用」，工業材料雜誌，2016 年 02 月刊，140-146 頁。

W. R. Backer and R. A. Dahlin, The effects of electrolytic assistance in peripheral grinding, Am. Sot. Mech. Eng. Pap., 60 WA-4, 1960.

Robert E. Phillips, Electrochemical Grinding, ASM Handbook 16 (1989) pp.542-547.

Pourbaix, M., Atlas of electrochemical equilibria in aqueous solutions, (2nd ed). Houston, United States: National Association of Corrosion Engineers (1974).

M. N. SHORT., MICROSCOPIC DETERMINATION OF THE OREMINERALS, WASHINGTON, UNITED STATES GOVERNMENT PRINTING OFFICE (1931) pp. 102-103.