擺線銑削SKD11工具鋼之切削參數特性探討

An Investigation on the Characteristics of Machining Parameters in Trochoidal Milling SKD11 Tool Steel

曾耀寬(Tseng Yao-Kuan)

指導教授 ： 簡文通

國立屏東科技大學/工學院/機械工程系所/碩士(2020年)

https://doi.org/10.6346/NPUST202000155

摘要

本研究之目的為利用擺線銑削所具有減低切削力的特性，探討大深度銑削SKD11工具鋼的影響。首先以Ø3.0mm的端銑刀與7.5mm的切削深度做為固定條件，使用田口法L9(34)直交表規劃實驗參數，以銑削後的底面、側壁表面粗糙度及材料移除率做為品質特性，再藉由變異數分析與TOPSIS評選同時考量多項品質的最佳參數組合，並與一般銑削方式比較討論。實驗結果經反應分析分別得到三種不同的最佳參數組合，各自進行確認實驗，得到的S/N比均落在預測值信賴區間內。再以TOPSIS評選的共同參數組合進行實驗，得到底面粗糙度為0.259μm、側壁粗糙度為0.328μm及材料移除率為489.75mm3/min，結果顯示可滿足精切削表面粗糙度為Ra0.4μm之限制，並可提升材料移除率。最後，以相同的材料移除體積與切削速度的條件下，比較一般銑削與擺線銑削的刀具磨耗與材料移除率。一般銑削時刀具的軸向離隙面磨耗平均值為70.64μm，刀腹磨耗平均值為62.2μm，材料移除率為429.03mm3/min；擺線銑削時刀具的軸向離隙面磨耗平均值為46.54μm，刀腹磨耗平均值為22.73μm，材料移除率為489.75mm3/min，結果顯示利用擺線銑削方式有利於減少刀具的磨損，並且當進行大深度銑削時，材料移除率可獲得更佳效果。本研究分析結果可做為切削工業選擇工法或調控參數達成品質改善與提升生產效率之參考。

關鍵字

擺線銑削 ； 田口法 ； TOPSIS ； 表面粗糙度 ； 材料移除率 ； 刀具磨耗

並列摘要

The objective of this study was to employ the characteristics of reducing the cutting force by the trochoidal milling and explore the impact of deep milling of SKD11 steel in tools. First, by adopting a fixed condition of Ø3.0mm end mill and 7.5mm cutting depth, while planning with the Taguchi’s L9(34) orthogonal method for the experimental parameters, the roughness of the bottom and side wall of milled surfaces, as well as the material removal rate, were used to describe the quality of milling. Then, through the analysis of variance and TOPSIS selection to consider the optimal combination of multiple quality parameters, the method would be compared with the general milling approach. The results yielded three different optimal parameter combinations through response analysis, and each was confirmed with experimentation with S/N ratios all fell within the confidence interval of the predicted value. Then, an experiment was carried out with the common parameter combination selected by TOPSIS, resulting in a bottom roughness of 0.259μm and a side wall roughness of 0.328μm, and the material removal rate was 489.75mm3/min, which showed that it could satisfy the limit of fine cutting surface roughness of Ra 0.4μm, not to mention an increase in the material removal rate. Lastly, under the same condition of material removal volume and cutting speed, the tool wear and the material removal rate of a trochoidal milling would be compared with those values of the general milling method. The average wear of the axial relief surface of the tool during general milling is 70.64μm, the average wear of the flank is 62.2μm, and the material removal rate is 429.03mm3/min. As for the trochoidal milling, the average wear of the axial relief surface was 46.54μm, the average flank wear was 22.73μm and the material removal rate was 489.75mm3/min, since the results showed that trochoidal milling was better in resistance to tool wear and more material removal rate when performing deep milling. The analysis results of this study could be referenced for the milling industry to choose construction method or control parameters to achieve quality improvement and increase production efficiency.

並列關鍵字

Trochoidal Milling ； Taguchi Method ； TOPSIS ； Surface Roughness ； Material Removal Rate ； Tool Wear

參考文獻

[1] Waszczuk, K., Karolczak, P., Wiśniewska, M., Kowalski, M., 2017, “Influence of the Path Type on Selected Technological Effects in the Trochoidal Milling,” Advances in Science and Technology Research Journal, Vol. 11, No. 1, pp. 147-153.

[2] Szalóki, I, Csuka, S., Csesznok, S., Sipos, S., 2012, “Can Trochoidal Milling Be Ideal?,” Conference of GTE on Manufacturing and related technologies, Vol. 5, pp. 1-10.

[3] 劉胤，劉軍，楊芸，焦剛，胡小秋，2010，「次擺線走刀在高速銑削窄槽結構中的應用」，宇航材料工藝，第40卷，第1期，第64-68頁。

[4] 陳晉昇，2015，以田口法運用於SCM415材料擺線銑削加工參數優化探討，碩士論文，龍華科技大學，機械工程系碩士班，桃園。

[5] 黃子浩，2018，以擺線工法切削Ti-10V-2Fe-3Al之分析研究，碩士論文，國立台灣科技大學，機械工程系，台北。