應用田口法於單點鑽石車削大角度模仁的加工參數最佳化之研究

Application of Taguchi method in the optimization of cutting parameters of single-point diamond turning for improving the surface quality of the large slope angle mold.

林忠興(Chung-Hsin Lin)

指導教授 ： 劉建宏

國立虎尾科技大學/電機資訊學院/光電與材料科技研究所/碩士(2009年)

摘要

近年來光電產業發展快速，為提升成像品質、滿足輕薄短小及低成本的產業需求，非球面塑膠鏡片被大量使用，以手機相機及藍光光碟機的讀取透鏡(blu-ray pick-up lens) 為例，都有往更大面角度的發展趨勢。目前已被廣泛使用的超精密鑽石車削技術，隨著產品品質需求的提升，對於形狀精度及表面粗糙度等品質特性要求也相對愈來愈高，因而探討大角度模仁的形狀精度及表面粗糙度之影響因素，俾使有效地提升工件的表面品質。
本研究是應用田口法探討超精密鑽石車削時表面品質最佳化的加工參數。實驗是以單點鑽石刀具對無電解鎳模仁車削加工，考量的加工參數有刀尖半徑、進給速度、主軸轉速、切削深度。透過直交表、信號/雜訊比、變異數分析，探討不同加工參數對形狀精度與表面粗糙度的影響。實驗結果說明使用田口法參數設計，最佳化加工性能，對於形狀精度的品質改善率有26.3%，同時也對表面粗糙度的品質改善率也有18.3%。

關鍵字

單點鑽石車削 ； 田口法 ； 表面粗糙度

並列摘要

The opto-electronics industry has been developed rapidly in recent years. In order to enhance image quality and meet the industry requirements for light weight, thinness, compactness and low cost, aspheric surface micro-lens has been widely used. For example, mobile cameras and blu-ray pick-up lens are both developed towards having large slope angles. As for quality properties such as form accuracy and surface roughness, the higher quality requirements of the product, the more restrict requirements for the ultra-precision machine technology widely used today. Accordingly, this thesis aims to investigate the factors effecting the form accuracy and surface roughness of large slope angle molds so as to enhance the surface quality of workpiece.
In this thesis, Taguchi method is applied to investigate the processing parameters for the ultra-precision machine technology to optimize surface quality. Experiments are done by using single-point diamond tools to cutting electroless- nickel molds. The processing parameters involved are insert radius, feeding speed, spindle speed, and depth of cut. The effects of said different processing parameters on form accuracy and surface roughness are examined through orthogonal array, signal-to-noise ratio and analysis of variance (ANOVA). The experiment results demonstrates how to use Taguchi method parameter design for optimizing machining performance that can effectively enhance form accuracy and reduce surface roughness.

並列關鍵字

single-point diamond turning ； Taguchi method ； surface roughness

參考文獻

[1]Jang,D.Y.and Seire,A.,1992,“ Machining Parameter Optimization for Specified Surface Conditions ”, Journal of Engineering for Industry,114(2),pp.254-257.

[2]Yellowey, I.and Adey, D.,1992,“ A New Approach to the Real Time Optimization of Turning Operation ”, Int. J. March. Tools Manufact.,32(3),pp.453-466.

[3]陳政忠，1995，「應用機器視覺於切削加工件之表面粗糙度分析」，碩士論文，元智大學，內壢。

[4]W.H. Yang, Y.S. Tarng *,“Design optimization of cutting parameters for turning operations based on the Taguchi method” Journal of Materials Processing Technology 84 (1998) 122–129

[5]M. Nalbant *, H. Gokkaya, G. Sur,“Application of Taguchi method in the optimization ofcutting parameters for surface roughness in turning” Materials and Design 28 (2007) 1379–1385