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論文名稱(中文) 弦波式鋸條之鋸削製程分析
論文名稱(英文) Analysis of sawing process for wave-type hack saw blades
校院名稱 成功大學
系所名稱(中) 機械工程學系專班
系所名稱(英) Department of Mechanical Engineering (on the job class)
學年度 98
學期 2
出版年 99
研究生(中文) 凌竟銘
研究生(英文) Ching-Ming Ling
學號 n1794106
學位類別 碩士
語文別 中文
論文頁數 63頁
口試委員 指導教授-王俊志
口試委員-李榮顯
口試委員-林昌進
口試委員-王俊志
中文關鍵字 鋸切  弦波式鋸條  比切削係數  切屑負載 
英文關鍵字 sawing  wave-type hack saw blades  specific coefficients  chip load 
學科別分類
中文摘要 本文探討弦波式鋸條鋸削製程之分析。目前尚未有研究團隊對弦波式鋸條鋸削製程中齒刃之切屑負載做深入分析,因此於鋸削加工時,無法得知鋸條中每個齒刃對材料移除的貢獻度。若能取得鋸條中每個齒刃之切屑負載,即可預測鋸條鋸削時優先失效之齒刃位置。透過鋸條齒刃切屑負載公式之建立,配合實驗所得之比切削係數,可有效解析弦波式鋸條之鋸削製程,並達到預測鋸條鋸削工件之結果。
本論文切屑負載之計算使用二種方法。第一種:推導公式,首先定義弦波式鋸條幾何參數,假設鋸削時每刃進給為定值,齒刃位移有等相位,則可推導鋸條齒刃切屑負載公式;此方法計算快速,但只限於齒刃位移有等相位為前提。第二種:軟體模擬,先測量鋸條齒刃的幾何參數,再將參數透過軟體模擬出工件被弦波式鋸條鋸削移除之情形,並計算出每個齒刃切屑負載;此方法須先測量鋸條齒刃之幾何參數且耗時,但齒刃位移可不受等相位條件限制。經計算後得知弦波式鋸條在弦波波谷位置之前一個齒刃有最大切屑負載,可推測此齒刃為鋸條鋸削時優先失效之齒刃。
弦波式鋸條之單一弦波有多個齒刃並呈弦波式排列。本研究選擇鋁合金AA6061-T651為切削工件,考慮以銑削工具機模擬鋸切運動行為,將鋸條研磨成不同齒刃數,做不同切削進給之切削實驗,並根據三維動力計量測判讀之結果,可取得比切削係數。最後以手弓鋸鋸切而驗證推導之鋸削模式,結果誤差約在20%。
英文摘要 This paper analyzes sawing process for wave-type hack saw blades. At present, there is none of research team assaying saw blade’s chip load of sawing process for wave-type hack saw blades. For this reason, the contribution for material detachment of each blade can not be known when sawing. If getting each blade’s chip load, it will be possible to forecast the first expiration blade. By establishing formula for chip load and cooperating with specific coefficients, sawing process for wave-type hack saw blades can be effectively analyzed and reach the goal in forecasting the result of the saw blade truncating work piece.
In this paper, calculate chip load by two ways. The first way, derive formula. First, make definition of wave-type hack saw blade’s geometric parameter, suppose each edge to feed is definite value and displacement of blade is equal. Then, formula of saw blade’s chip load can be derived. This way is quick for calculating, but it’s based on the premise that overlap of blade has the order. The second way, simulate by soft ware. Survey saw blade’s geometric parameter advance, which be simulated by soft ware to get circumstances of work piece detachment that sawed by wave-type hack saw blades, and calculate each blade’s chip load. This way is time-consuming and must survey saw blade’s geometric parameter advance, but overlap of blade is not be limitative. As a result by calculating, the preceding blade in wave trough of wave-type hack saw blades has the maximum of chip load. Therefore, the blade can be broken as the first expiration one.
A wave-type of hack saw comprises many teeth, ranked as the sine wave. The work piece is a rectangular of Aluminum alloy AA6061-T651 of this study. Considering of simulating sawing model by milling machine, choose the wave-type hack saw blades and grind different tooth used grinding machine, different feed per tooth for experiment. A dynamometer is mounted on the table of the machine. The three directional cutting force signals from the dynamometer are collected by the computer through the A/D converter. According to three directional cutting force and cutting area, specific coefficients can be obtained. Finally, use the hack saw to cut work piece by hand to prove the cutting force model, the error is about 20%.
論文目次 總目錄
中文摘要…………………………………………………..………I
英文摘要………………………………………………….……III
誌謝……….……………………………………...........……V
總目錄……………………….……………………………...……VI
表目錄………………………………………….………..……VIII
圖目錄………………………………….…………………...……IX
符號說明……………….……………………………………......……XIII
第一章 緒論.………………………..………………….………1
1.1 前言……………………………………….…….………1
1.2 文獻回顧……………………………………….………2
1.3 研究動機及目的………………………………………4
1.4 研究方法與範疇………………………………………4
第二章 鋸切力模式的建立…………….…………………….6
2.1 前言………….….…….….…………….…….…………..6
2.2 比切削係數定義……..….…….………………………..6
2.3 切屑負載推導…….….….…….…………..….………..8
第三章 鋸條參數測量及切屑負載計算………..……………...14
3.1 前言……………………….…………………..………..14
3.2鋸條各參數測量……………….………..…………………14
3.3模擬方式計算切屑負載……..…..…………………………17
3.4 推導公式計算切屑負載………………………………………….22
第四章 實驗規劃與實驗結果……………………………………25
4.1 前言……………………..…………………...……….25
4.2 第一部份(取得比切削係數) ……………..………26
4.2.1實驗規劃…………………………………..26
4.2.2 實驗設備與裝置……………..………….26
4.2.3實驗步驟…………………………………..29
4.2.4 實驗結果………………………………….30
4.3 第二部份(切削力模式驗證) …………….…….……52
4.3.1 實驗規劃與裝置……………..………………52
4.3.2 實驗結果理論預測…………………………….53
4.3.3 實驗結果……………………………………….54
第五章 結論與建議………………………………………….59
5.1 結論……………………………………………………59
5.2 建議……………………………………………………60
參考文獻…………………………………………………………61

表目錄
表3-1鋸條(a)測量數據……………………….……..16
表3-2鋸條(b)測量數據…………………….………..17
表 4-1 鋁合金AA6061-T651機械性質表…………..…..…27
表4-2 第一部份實驗規劃表………………………………...30
表4-3 A1到E7的數據整理總表………………………….49
表4-4 手弓鋸鋸削實驗規劃表………………………………53
表4-5理論預測結果…………………..……………………53
表4-6 手弓鋸鋸切實驗結果…………………………………58
表4-7 預測值與實際值的比較表………………..…………58

圖目錄
圖1.1 鋸條鋸齒的排列型態……………………..……………2
圖2.1 鋸條鋸削工件示意圖…………………..………………7
圖2.2弦波式鋸條三視圖…………………………………..…9
圖2.3齒刃偏擺的位移S與振幅R的關係圖………..……10
圖2.4弦波式鋸條側視示意圖……………………………....11
圖2.5弦波式鋸條鋸削示意圖………………………….….12
圖3.1光學顯微鏡與影像擷取電腦…………………….…..14
圖3.2齒刃偏移量S測量示意圖…………………………....15
圖3.3鋸條(a)之正視圖及下視圖……………..…….…..15
圖3.4鋸條(b)之正視圖及下視圖…………..………..….16
圖3.5切屑負載模擬架構流程圖..…………………..….18
圖3.6 三個弦波齒刃鋸削工件示意圖(tx=0.02 mm) ….…20
圖3.7 三個弦波齒刃鋸削工件示意圖(tx=0.05 mm) ….…20
圖3.8模擬齒刃切屑負載圖……………………..……….……21
圖3.9 齒刃切屑負載百分比柱狀圖………………..…….……22
圖3.10公式計算之切屑負載柱狀圖(tx=0.02mm)………………….23
圖3.11公式計算之切屑負載柱狀圖(tx=0.05mm)………………….24
圖4.1 磨除齒刃後之鋸條………………………….…………26
圖4.2 實驗設備的安裝示意圖………….……………..……28
圖4.3 實驗設備實際安裝圖………………………………….28
圖4.4 A1條件鋸切三軸向切削力………………………….30
圖4.5 B1條件鋸切三軸向切削力………………………….31
圖4.6 C1條件鋸切三軸向切削力………………………….31
圖4.7 D1條件鋸切三軸向切削力………………………….32
圖4.8 E1條件鋸切三軸向切削力………………………….32
圖4.9 A2條件鋸切三軸向切削力…………………….33
圖4.10 B2條件鋸切三軸向切削力………………………….33
圖4.11 C2條件鋸切三軸向切削力………………………….34
圖4.12 D2條件鋸切三軸向切削力………………………….34
圖4.13 E2條件鋸切三軸向切削力………………………….35
圖4.14 A3條件鋸切三軸向切削力………………………….35
圖4.15 B3條件鋸切三軸向切削力………………………….36
圖4.16 C3條件鋸切三軸向切削力………………………….36
圖4.17 D3條件鋸切三軸向切削力………………………….37
圖4.18 E3條件鋸切三軸向切削力………………………….37
圖4.19 A4條件鋸切三軸向切削力………………………….38
圖4.20 B4條件鋸切三軸向切削力………………………….38
圖4.21 C4條件鋸切三軸向切削力………………………….39
圖4.22 D4條件鋸切三軸向切削力………………………….39
圖4.23 E4條件鋸切三軸向切削力………………………….40
圖4.24 A5條件鋸切三軸向切削力………………………….40
圖4.25 B5條件鋸切三軸向切削力………………………….41
圖4.26 C5條件鋸切三軸向切削力………………………….41
圖4.27 D5條件鋸切三軸向切削力………………………….42
圖4.28 E5條件鋸切三軸向切削力………………………….42
圖4.29 A6條件鋸切三軸向切削力………………………….43
圖4.30 B6條件鋸切三軸向切削力………………………….43
圖4.31 C6條件鋸切三軸向切削力………………………….44
圖4.32 D6條件鋸切三軸向切削力………………………….44
圖4.33 E6條件鋸切三軸向切削力………………………….45
圖4.34 A7條件鋸切三軸向切削力………………………….45
圖4.35 B7條件鋸切三軸向切削力………………………….46
圖4.36 C7條件鋸切三軸向切削力………………………….46
圖4.37 D7條件鋸切三軸向切削力………………………….47
圖4.38 E7條件鋸切三軸向切削力………………………….47
圖4.39 主切削力Fx與每刃進給tx 關係散佈圖………..………..50
圖4.40 比切削係數ktx與切削厚度關係散佈圖………………..50
圖4.41比切削係數ktx與未變形切削面積A 關係散佈圖…51
圖4.42 實驗用手弓鋸裝置圖……………..……………….52
圖4.43 T1鋸削實驗三軸向力與時間關係圖……..………54
圖4.44 T1鋸削實驗工件切削面………………..…………54
圖4.45 T2鋸削實驗三軸向力與時間關係圖……………..55
圖4.46 T2鋸削實驗工件切削面…………………………..55
圖4.47 S1鋸削實驗三軸向力與時間關係圖………..…..56
圖4.48 S1鋸削實驗工件切削面…………………………..56
圖4.49 S2鋸削實驗三軸向力與時間關係圖……………..57
圖4.50 S2鋸削實驗工件切削面…………………………..57
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