玻璃基板於不同冷卻潤滑條件高速銑削性能之研究

A Study on Cutting Performance under Different Cooling/Lubrication Conditions for Glass-Substrate High-Speed Milling

陳治宇(Zhi-Yu Chen)

指導教授 ： 林盛勇

國立虎尾科技大學/工程學院/機械與電腦輔助工程系碩士班/碩士(2013年)

摘要

近年來，玻璃基板已逐步成為資訊產品產業發展的重要材料，其需求量不斷增加，對於它各種加工品質的要求也日益嚴苛。目前從事玻璃加工的產業大都以切割及磨削的方式為主，加工製程較為繁雜且成本也較高，所以尋求縮短製程及有效節省成本等方面的突破，乃當前加工技術之重要課題。由於玻璃具有高強度、高硬度及低導熱性等性質，在加工過程中刀具易產生快速磨損，加工表面易產生裂紋及邊緣崩角等缺陷。為改善上述問題，本文採用高轉速、低切削深度與冷卻液，同時搭配適當的進給率進行側銑削，期能掌控韌脆銑削轉換的模式，以提高玻璃基板加工效率，同時增進表面品質的提升與生產成本的降低。
本研究運用大量與中量水溶性切削液及綠色製造技術MQL以彩鑽碳化鎢刀具執行玻璃基板之銑削實驗。於銑削實驗過程中使用動力計與頻譜分析儀分別監測切削力及振動量，再以工具顯微鏡觀察在不同實驗參數下的玻璃邊緣表面品質與刀具磨耗，進行實驗數據分析探討。結果顯示，與傳統中量澆注濕銑削及MQL相比，大量澆注濕銑削提供銑削加工區良好的冷卻效果，減少刀具的磨損有助於切削力的降低。從切削動態振動量觀察可得知，添加水溶性切削液有助改善且降低切削振動之情形並提供穩定的銑削行為。另從材料邊緣破損觀察可得知，在高切削速度、低進給率及淺徑向切深，可得到較好的玻璃邊緣表面品質。且施加水溶性切削液可有效降低在玻璃表面加工過程中產生的大量熱量，從而避免玻璃產生破裂現象。由刀具磨損量測實驗可觀察出，在銑削過程中施加水溶性切削液當切削深度增加時，刀腹表面會隨著進給率的提升而產生明顯的凹痕損傷，而施以MQL加工對於刀具切刃會產生崩角及刃口大範圍崩裂。綜觀整體銑削性能表現可得知，提高切削速度與降低切削深度及進給率可有效降低玻璃基板邊緣破損的發生，提升刀具壽命，獲得較佳的邊緣表面品質。

關鍵字

玻璃基板 ； 銑削 ； 邊緣崩角 ； 刀具磨耗

並列摘要

In the recent year, the glass substrate has become gradually the most important material of the development in the information technology enterprise, its demanding quantity is increasing higher and higher, the quality of various processing have been requested more severer. For the time being, the enterprise of glass processing is mainly on cutting and edge seaming, the process flow is complicated and the cost is higher, therefore , the important topics of the current processing technology are seeking for the breakthrough of short process and the efficient cost saving . Because the glass possesses the quality of high intensity, high stiffness and low thermal conductivity, it is easy to make the cutting tool have the fast abrasion in the processing period and have imperfections like cracks and edge/corner collapse on the processing surface. To improve the above problems, the high rotation speed and low cutting depth and cooling fluild are employed in this study, also collocates the suitable feed rate and proceed the side milling/cutting, control the tough and brittle milling/cutting transformation model hopefully, thus, improve the processing efficiency of the glass substrate.

The study employs large and medium water- soluble cutting fluid and green Production technique MQL and uses the diamond Tungsten Carbide (WC) cutting tool to proceed the milling/cutting experiment of the glass substrate. During the milling/cutting experiment, dynamometer and spectrum analyzer are employed to monitor the cutting force and vibration quantity, respectively. Also, observing the quality of edge surface of glass and the abrasion of cutting tool under different experiment parameters by tool-microscope off-line. The experimental data are analyzed under numerical analysis. Results show that the comparison between the traditional medium quantity of pouring wet milling/cutting and MQL, large quantity of pouring wet milling/cutting provide a good quenching effect on processing zone, thus, reduce the abrasion of the cutting tool and contribute to lower the cutting force. Observing from the cutting dynamic vibration quantity reveals that adding the water- soluble cutting fluid will contribute to improve and lower the cutting vibration and provide the stable action of cutting. Another observing from the damage of the raw material edge reveals that the better surface quality of the glass edge is obtained under high cutting speed, low feed rate and shallow path cutting. Adding the water- soluble cutting fluid can lower effectively the large amount of heat which is generated in the processing period of the glass surface. The high temperature difference between the surface and the inner layer of the glass is avoided, thus, the internal stress of the glass increases and over the limited intensity of the glass itself, then, leads to the break of the glass. Observing from the abrasion quantity of the cutting tool reveals that adding the water- soluble cutting fluid in the milling/cutting period, when increasing the cutting depth, the apparent dent damage will appear on the abdomen part of the cutting tool as the feed rate is increasing. Applying the MQL processing will make the cutting tool collapse the edge and shell off on its front end. Making a comprehensive survey of all the performance of milling/cutting, raising the cutting speed, lowering both of the cutting depth and the feed rate will reduce the occurrence of damage of glass substrate edge effectively, upgrade the cutting tool life and obtain the better quality of edge surface.

並列關鍵字

Glass substrate ； milling ； edge-indentation ； tool wear

參考文獻

[31] 楊忠義、許富銓、蕭美技、李正雄，超音波振動輔助加工於玻璃材料加工研究，工程科技與教育學刊，Vol.7 (2010), pp.64-74.

[1] F.Z. Fang, G.X. Zhang, An experimental study of optical glass machining, Int. J. Adv. Manuf. Technol.Vol.23 (2004), pp.155-160.

[2] Z.P. Wan, Y. Tang, Brittle–ductile mode cutting of glass based on controlling cracks initiation and propagation, Int. J. Adv. Manuf. Technol. Vol.43 (2009), pp.1051-1059.

[3] R. Zitoune, F. Collombet, F. Lachaud, R. Piquet, P. Pasquet, Experiment-calculation comparison of thecutting conditions representative of the long fiber composite drilling phase, Compos. Sci. Technol.Vol.65 (2005), pp.455-466.

[4] K. Liu, X. Li, S.Y. Liang, X.D. Liu, Nanometer-Scale, Ductile-Mode Cutting of Soda-Lime Glass, J. Mater. Process. Technol. Vol.7 (2005), pp.95-101.