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研究生: 李柏緯
Lee, Po-Wei
論文名稱: 放電加工參數影響鋁合金6061加工特性之研究
The Study Of Electric Discharging Machining Parameters Influencing The Machining Characteristics Of Aluminum Alloy 6061
指導教授: 郭金國
Kuo, Chin-Guo
學位類別: 碩士
Master
系所名稱: 工業教育學系
Department of Industrial Education
論文出版年: 2016
畢業學年度: 104
語文別: 中文
論文頁數: 58
中文關鍵詞: 放電加工疲勞壽命田口實驗法品質監控電漿蝕刻
英文關鍵詞: die sinking electric discharge machining, fatigue life, taguchi methodx, quality control, plasma etching
DOI URL: https://doi.org/10.6345/NTNU202204922
論文種類: 學術論文
相關次數: 點閱:188下載:25
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  • 本研究探討放電加工參數影響鋁合金6061加工特性之研究。以紅銅為電極,固定脈衝時間、休止時間、排渣高度、放電電壓,改變放電電流8 A~15 A,探討放電加工特性包括:電極消耗率、材料移除率、表面粗糙度、變質層厚度、疲勞壽命。為了監控放電加工過程品質處於控制狀態,本研究將最佳放電加工參數重複多次實驗 (35次),觀察鋁合金 (6061)放電加工特性,配合品質管制圖,達到監控預測的效果。
    研究結果顯示,較高的放電電流 (15 A),有較大的材料移除率,電極消耗率,表面粗糙度及工件表面硬度。此外、增加放電電流,變質層厚度亦隨著增加(由10.31 μm 增加到19.38 μm),因為變質層硬度遠高於母材,故工件疲勞壽命隨之提升。
    經多次 (35次)重複放電加工,透過品質管制圖(Shewhart control chart)監控,顯示該放電加工特性始終保持在穩定可監控狀態。
    此外,應用電漿蝕刻放電加工件表面,進一步提升放電加工件疲勞壽命。配合田口實驗設計L9 (33),探討電漿蝕刻參數:蝕刻功率 (W)、氧氣流率 (sccm)、蝕刻時間 (min)對放電加工件表面粗糙度、水滴接觸角、疲勞壽命的影響。以掃描式顯微鏡(SEM),觀察放電加工件表面形貌及變質層。研究結果顯示,放電加工件經電漿蝕刻,可有效清除工件表面殘渣及微細裂紋,降低微裂紋對工件的不良影響,有效提升放電加工件疲勞壽命約25%。

    The study tested electric discharging machining parameters influence the machining characteristics of aluminum alloy 6061. With copper as the electrode, Fixed pulse time, Slag height, discharge voltage, and change discharge current 8 A~15A. To investigate EDM features including electrode consumption rate, material removal rate, surface roughness, recastlayer and fatigue life. In order to monitor the quality of the discharge process in control, the optimal discharge machining parameters repeated experiments (35 times) , observed an aluminum alloy (6061) discharge machining characteristics, with quality control charts, to monitor the predicted effect.
    The results showed a high discharge current (15A) with a larger material removal rate, electrode consumption rate, surface roughness and surface hardness. In addition, increasing the discharge current, recastlayer thickness also increases (from the 10.31 μm to 19.38 μm), due to affected layer hardness is much higher than the base material, so the fatigue life rise with the workpiece.
    After repeated (35 times) discharge machining experiments, through quality control charts (Shewhart control chart) monitor the discharge machining characteristics remain in a stable state.
    Moreover, the application of plasma etching the surface discharge machining, in further, enhance fatigue life of electrical discharge machining parts.,Investigated plasma etch parameters: etching power (W), oxygen flow rate (sccm), etching time (min) for the influence of electrical discharge machining surface roughness, water contact angle and fatigue life. With scanning electron microscope (SEM), observe the surface morphology and recastlayer.
    The experimental result shows that the EDMed workpiece by plasma etching, remove surface residue and micro-cracks effectively, reducing the adverse effects of micro-cracks, the fatigue life of EDMed workpiece can be improved.

    摘要.....................................i Abstract................................ii 誌謝....................................iv 目錄.....................................v 表目錄.................................vii 圖目錄................................viii 第一章 緒論..............................1 1.1 前言.................................1 1.2 研究動機與目的.......................3 第二章 理論背景與文獻回顧...............5 2.1放電加工原理..........................5 2.1.1 放電加工參數.......................8 2.1.2 放電加工件表面形貌................10 2.2 電漿原理............................12 2.3 田口實驗法..........................14 2.3.1 因子的分類........................15 2.3.2 數據分析法........................17 2.4 疲勞理論............................19 2.4.1 疲勞機制..........................21 2.5 放電加工相關文獻回顧................23 第三章 實驗方法.........................25 3.1 實驗步驟............................25 3.2 實驗材料............................28 3.3 實驗儀器及設備......................29 第四章 實驗結果與討論...................35 4.1 放電加工條件的影響..................35 4.1.1 電極消耗率........................35 4.1.2 材料去除率........................35 4.1.3 放電後表面粗糙度分析..............36 4.1.4 放電加工件疲勞壽命分析............37 4.2 品質管制圖..........................41 4.3 電漿蝕刻放電加工件表面..............45 4.3.1 電漿蝕刻影響放電加工件表面粗糙度..45 4.3.2 電漿蝕刻影響放電加工件水滴接觸角..47 4.3.3 電漿蝕刻影響放電加工件疲勞壽命....51 4.3.4 最佳參數驗證......................54 第五章 結論.............................55 參考文獻................................57

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