一直以來工具機所使用的刀具,不論是銑刀、鑽頭、絞刀等都是製造業最重要也是最不可或缺的工具,由於近年來3C科技產業蓬勃發展而智慧型手機與其他產品更是如此,而現代人挑選3C用品的時候不再一昧地講求性能,產品的外觀、顏色與重量更是成為人們在購買產品時的重點之一,所以現今各式各樣的材料,如本文所討論的工程塑膠或是鈦合金與鋁合金等都漸漸地被拿來加工製作成手機殼或各式各樣的智慧型產品,然而如何提升刀具在銑削工程塑膠時的刀具壽命與加工後的工件表面品質為本論文研究的課題。 本論文將分為兩個部分,分別為刀具幾何角度之最佳化分析和刀具研磨效能最佳化分析,所使用的刀具為「左旋右刃」的單刃端銑刀,所銑削的工件為「聚碳酸酯+矽氧烷」所聚合而成的工程塑膠,將使用田口法實驗配置本論文第一部分「刀具幾何角度最佳化分析」與第二部分「刀具研磨效能最佳化分析」,所使用的田口法直交表為L_9 (3^4 )和L_32 (2^(1 ) 〖x 4〗^9 )。第一部分選擇的因子為端銑刀最重要之幾何角度:切削角與離隙角,實驗目標是為了增加刀具壽命與減少工件毛邊,經由變異數分析與多品項分析後發現,影響刀具磨耗的主要因子為「離隙角」而影響工件毛邊大小的主要因子為「切削角」。第二部分所使用的因子為研磨刀具時最重要的參數:砂輪線速度(sfm)、進給(feed)與粒度(SDC),實驗目標主要係為減少研磨刀具時所需的時間與提升刀具品質,如:刀刃口平整度、刀面與刀腹之粗糙度,經由變異數分析與多品項分析後發現,影響刀刃口平整度的主要因子為「排屑槽之砂輪粒度」,排屑槽為研磨本論文所探討的刀具時最後一道程序,因此只要將該顆砂輪的粒度挑選好,其他較不重要的工程皆可加快進給,這樣不僅可以達到良好的研磨品質亦可減少研磨刀具時所需的時間。
Due to the prosperity of 3C technology, milling cutters, drills or reamers of the machine tools are essential to manufacturing industry in recent years. More and more people pay attention to the appearance, color and weight of 3C products, instead of the functions. Therefore, there are a variety of materials processed into smartphone shells and intelligent products, such as the engineering plastic, titanium, or aluminum. This study emphasizes how to improve the tool life and the surface quality of the machining workpieces. The end mills used in the experiments are the single-blade cutter and the milling workpieces are the polycarbonate plus siloxane that is the polymerization of engineering plastics. This thesis divides into two parts. The first part is the analysis of tool geometry optimization and the second part is tool grinding efficiency optimization. Both of them used the experimental configuration Taguchi method which is L9 (34) and L32 (21 x49). The most important geometry of end mills in the first part is the rake angle and the relief angle. The goal of the experiment is to increase tool life and reduce the flash of workpieces. The analysis of variance and multiple characteristics analysis showed that the main factors affecting tool wear is the relief angle and affecting the flash is the rake angle. The factors in the second part are the most important parameter when milling cutting tools. They are the surface speed of a wheel, feed, and grain size. The main target of the second experiment is to reduce processing time of tool grinding and improve the quality of tools, such as the surface roughness of flank of end mills and the flatness of cutting edges. We found the principal parameter is the grain size of the fluting wheel by the variance and multiple characteristics analysis when we discussed the flatness of the cutting edges. The flute is the last part of the entire machining procedure, we could pick a better grain size of the fluting wheel and improve the feed of the others procedures. Experiments showed that one could obtain the better grinding quality, and spend the less time for the grinding procedures.