難削材切削性能與加工技術之研究

A Study of Cutting Performance and Cutting Strategy for Difficult-to-cut Materials

鄭元祐(Yuan-Yo Cheng)

指導教授 ： 林盛勇

國立虎尾科技大學/工程學院/創意工程與精密科技研究所/碩士(2009年)

https://doi.org/10.6827/NFU.2009.00036

摘要

隨著航太科技與生醫科技的蓬勃發展，鎳基超合金與鈦合金等難加工合金的應用也日益廣泛，因其在高溫具有良好機械性質、高強度、高溫耐蝕性。能否高效率加工這些材料，關係到汽車、航太、生醫、石化和民生用品等等重要工業的發展速度。因此必須解決切削難加工材所帶來的難題，加快關鍵技術的開發應用和創造新的加工技術來滿足製造業的需求。
本文旨在開發難加工材料切削之關鍵技術，利用有限元素法建立一套鈦合金Ti-6Al-4V銑削及鎳基超合金Inconel718超音波輔助車削模型，藉由此模型探討不同參數時切屑形成的過程，切屑和工件的切削溫度分佈、切削力和等效應力等物理量的變化。實驗方面則是使用水性切削液與油性切削液銑削鈦合金及利用超音波輔助並配合液態氮冷卻來車削Inconel718，將超音波產生機架設在刀具上，其振動方向為切線方向，並利用動力計所量測的切削力與表面粗糙度輪廓測定器量測到的表面粗糙度值，進行分析與探討。結果顯示：利用鈦合金銑削與Inconel 718車削實驗結果與模擬結果作驗證，其切削力大小是接近的，證實此模型是可被使用的。模擬鈦合金銑削時，其切屑為鋸齒狀切屑。銑削實驗使用油性切削液時，在高切削速度、低進給率和淺軸向切深，可以得到較好的表面粗糙度。模擬Inconel718車削時，發現超音波輔助車削可有效的降低其切削力。車削實驗時，利用超音波輔助並配合液態氮冷卻，可降低其切削力，對於表面粗糙度也有極大的改善。由以上的幾點結果，冀望能對難切削材加工之參數規劃有所幫助，有助於提高實際加工時成品的尺寸精度和改善成品品質，並且設計出切削過程之最佳參數。

關鍵字

鈦合金Ti-6Al-4V ； 鎳基超合金Inconel718 ； 超音波輔助車削 ； 鋸齒狀切屑

並列摘要

As the vigorous development of aerospace and medical technology. Titanium alloy and nickel-base superalloy has been widely utilized in various applications, because they have good mechanical property, high strength and good corrosive resistance to high temperature. For these reasons whether high efficiency to machining these materials or not, related to the development of automobile, aerospace, medical, and petrochemical industry. So the encountered great difficulties in machining difficult-to-cut materials must be solved. To development and application of key technologies be quickly, and create new cutting technology, so as to meet the demand of manufacture industry.
The main purpose of study is to develop key technologies for machining difficult-to-cut materials. Construct the titanium alloy of milling and Inconel 718 of ultrasonically assisted turning models using finite element method. The changes of chip shape, cutting temperature, cutting force and effective stress with different cutting conditions are analyzed. The experiments using different cutting fluids to milling titanium alloy； combine ultrasonically assisted and liquid nitrogen to turning Inconel 718. When turning Inconel 718, tangential direction as the direction for ultrasonically assisted vibration. The cutting performance has been investigated and analyzed in terms of cutting force, surface roughness and tool wear. Results show that a good agreement of cutting force was found between simulation and experiment. This demonstrates the developed model in this study can be used. And using this model to simulate titanium alloy cutting, serrated chip produced is obviously. Using oil cutting fluid to milling titanium alloy under high cutting speed, low feed rate and small depth of cut, good surface roughness can be obtained. Turning of Inconel 718 by combining ultrasonically assisted and liquid nitrogen has an advancement of reduced cutting force and enhanced workpiece surface quality. From the above results, design of optimization parameter to increase surface finish precision and cutting quality for machining difficult-to-cut materials, expectantly.

並列關鍵字

titanium alloy Ti-6Al-4V ； nickel-base superalloy Inconel718 ； ultrasonically assisted turning ； serrate chip

參考文獻

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