本研究針對外徑車刀把進行切削穩定性分析，並以主軸轉速調變法來抑制顫振，同時發展具偵測刀把振動及切削力功能之感測器模組。首先經由三維動態車削系統化簡獲得二維模型，並以實驗求得製程剛性矩陣之切削常數及結構撓度矩陣之模態參數，建立切削穩定性解析模式。接著以數值模擬考量不同切削力模型、製程阻尼及非線性之切屑厚度變化的作用，建立各切削常數組合之穩定葉瓣圖，再以切削實驗結果比較各模型準確度，結果顯示含製程阻尼之剪犁分離效應切削常數模式與實驗結果最為相符。本文以主軸轉速弦波調變法抑制顫振，以現有之最小振動能量法為基礎，使用數值方法之時域模擬修正弦波調變振幅與轉速兩種控制參數，並探討控制參數對顫振抑制的效果，發現增加調變振幅提高抑振能力，但調變頻率在達到一定數值後對抑振的貢獻趨於定值，最後透過變轉速車削顫振抑制實驗確認模擬與分析結果。為監控及分析切削振動與切削力，本研究發展一套置於刀把上量測加速度與切削力之低成本感測器模組，包含可量測200 g高加速度之整合式三軸微機電加速規模組以及基於應變規之切削力量測模組。

Chattering of machine tool such as lathe during cutting is traditionally an annoying and dangerous problem encountered in manufacturing. How to control machine chatter is thus a nontrivial task for years. In this article, the dynamics of turning cutting is modelled and simulated for exploring the feasibility to suppress chattering using spindle speed variation technique. In parallel, a conventional manual lathe equipped with a self-designed sensor module is served as the experiment carrier for evaluating the performance. The results indicated that the simulation prediction agree with experimental data essentially and this ensures the feasibility. In order to measure and analyze physical quantities from cutting process effectively, a sensing module which can measure vibration and cutting force is evolved for external turning. Three-axis integration MEMS accelerometer is developed, which is combined with three single-axis accelerometers. The integration of MEMS accelerometer solves the problem that too large acceleration causes piezoelectric accelerometer to fail. In addition, quick-release connector for industrial target is also contained, which lets tool holder change faster. Furthermore, lightweight is considered also. Strain gage is used to measure cutting force. Transfer matrix between force and strain is built, which converts strain from cutting experiments into cutting force. Both lumped global cutting constants (LGCC) and dual-mechanism global cutting constants (DGCC) models are adopted in analytical prediction and numerical simulation. Furthermore, process damping has also been added into numerical simulation, results of which are compared with cutting experiments. The critical stable depth of cut of DGCC model with process damping is shown to agree with experimental results. Sinusoidal spindle speed variation is further used to suppress turning chatter. Numerical simulation is used to find out the possible parameters to be applied in cutting experiments. Currently, optimization of spindle speed variation is underway for further improving chattering control.

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