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研究生： 陳亭萱
Chen, Ting-Hsuan
論文名稱： 運用長脈衝雷射大面積精密拋光技術於SKD61模具鋼之系統參數最佳化設計與改質層微結構分析之研究
Optimization of Process Parameters of Large Area Polishing and Microstructure Study of the Heat Affected Zone of the SKD 61 Tool Steel Using Long Pulse Laser
指導教授： 林仁輝
Lin, Jen-Fin
學位類別： 碩士
Master
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2014
畢業學年度： 102
語文別： 中文
論文頁數： 152
中文關鍵詞： 雷射拋光 、表面粗糙度 、改質層 、田口實驗設計
外文關鍵詞： laser polishing, surface roughness, worked layer, Taguchi method
相關次數： 點閱：183  下載：9 
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    • 本文之研究目的為以長脈衝摻鐿光纖雷射(Ytterbium-doped fiber laser, Yb:fiber laser)對SKD61工具鋼進行大面積之精密雷射拋光加工。
    本研究將進行三個階段的實驗，分別為田口實驗設計、全因子實驗及重要因子水準改變實驗，探討與雷射拋光有關之六個加工參數：脈衝功率、掃描速度、脈衝寬度、掃描頻率、重疊率及離焦量，對於SKD61試件之表面粗糙度與表面形貌的影響，藉由三維粗度儀量測而得之表面粗糙度、空間傅立葉分析、材料承壓比曲線及轉移函數，找出可以達到符合要求之表面粗糙度及平坦度之拋光參數組合，以作為對大面積試片拋光加工之參考依據。另外，雷射拋光的過程中將會產生改質層，由於本研究使用之SKD61工具鋼主要用於製作模具，改質層的厚度、硬度、彈性模數將會影響其磨耗性質，因此在進行雷射拋光的前後，需對SKD61工具鋼試件進行各種微結構分析，本實驗中利用掃描式電子顯微鏡、奈米壓痕計、聚焦離子束、往復式磨耗試驗機及X光繞射儀等等設備進行量測，以比較拋光前後之微結構材料特性之改變。為了加以預測雷射拋光之溫升及改質層厚度，本研究利用Comsol多物理場耦合軟體，以熱傳、流體及表面驅動流方程式建立理論模型，模擬SKD61工具鋼受脈衝雷射加熱後之溫度分佈及改質層厚度。
    根據拋光實驗之結果，試件之表面粗糙度可由0.283μm降至0.150μm，改善了47%；而由空間傅立葉分析可知，與雷射拋光掃描方向垂直之形貌會有效地降低其振幅，平行方向之形貌則與固化後形成之波紋有關。並綜合表面粗糙度、空間傅立葉分析及材料承壓比分析，可找出SKD61工具鋼之最佳雷射拋光加工條件。由微結構檢測可知，改質層厚度會隨雷射劑量及熔池中最高溫的增加而增加，硬度及彈性模數則會隨雷射劑量的增加而下降；此外，改質層的厚度與磨耗率有正比的關係；磨耗係數則會隨表面粗糙度增加而增加。由X光繞射分析則可知鐵(110)之強度越高，殘留應變會越高。經由數值分析而得之改質層厚度與實驗值比較有14.37%的誤差。

    In the present study, SKD61 tool steel specimen were polished by a long pulsed Yb:fiber laser system. In order to define the workable range and achieve the mean areal surface roughness (SRa) as small as possible, the laser operating conditions were designed at three stages. The experiments of three stages includes Taguchi method, all factors experiments and change-levels of the important factors. And six adjusted parameters of laser polishing are the laser power, the scanning velocity, the pulse duration, the scanning frequency, the overlap percentage and the focal offset. By measuring the surface roughness, the spatial Fourier analysis, the material ratio and the transfer function, the optimization of process parameters of large area polishing can be found. And the microstructure of the heat affected zone also be study to realize the influence of laser polishing.

    摘要 I Extended Abstract III 致謝 VI 目錄 IX 表目錄 XV 圖目錄 XVII 第一章 緒論 1 1-1 前言 1 1-1-1研究背景 1 1-2 文獻回顧 4 1-3 研究動機與項目 8 1-3-1研究動機 8 1-3-2研究項目 9 1-4 研究架構 10 第二章 相關雷射拋光理論 12 2-1 雷射理論 12 2-1-1雷射產生機制[64] 12 2-1-2光纖雷射[65] 13 2-1-3雷射與材料的交互作用[66] 14 2-1-4雷射拋光機制[68] 16 2-1-5雷射拋光加工重要參數 17 2-2 表面粗糙度 20 2-2-1表面粗糙度定義[71] 20 2-2-2表面粗糙度量測方式 21 2-2-3表面粗糙度表示法[73] 22 2-3 數值理論 24 2-3-1連續方程式 25 2-3-2能量方程式 25 2-3-3相變化(Phase change)方程式 26 2-3-4動量方程式 28 2-3-5表面張力驅動流方程式 28 2-4 表面形貌及改質層微結構分析之理論 29 2-4-1奈米壓痕試驗理論 29 2-4-2磨耗理論[80] 30 2-4-3空間傅立葉分析(Spatial Fourier analysis)理論 32 2-4-4轉移函數(Transfer function)理論 33 2-4-5殘留應變理論[81] 34 第三章 田口實驗設計法 44 3-1 田口實驗設計法簡介 44 3-2 參數設計[48.49] 45 3-3 因子分類(Factor Classification) 46 3-3-1控制因子(Control factor) 46 3-3-2雜音因子或干擾因子(Noise factor) 46 3-3-3信號因子(Signal factor) 46 3-4 品質損失函數(Quality Loss Function) 46 3-4-1望目特性(Nominal-the-best, NB) 47 3-4-2望小特性(Smaller-the-better, SB) 48 3-4-3望大特性(Larger-the-better, LB) 48 3-4-4 不對稱型品質特性(Asymmetrical quality characteristic) 48 3-5 直交表(Orthogonal Array) 48 3-6 信號雜訊比（Signal to Noise ratio） 49 3-6-1望目特性(Nominal-the-best )S/N比 50 3-6-2望小特性(Smaller-the-better)S/N比 50 3-6-3望大特性(Larger-the-better )S/N比 50 3-7 變異數分析(Analysis of Variance, ANOVA) 51 3-7-1要因(Source) 51 3-7-2平方和(Sum of Squares；SS) 51 3-7-3自由度(Degree of Freedom；DOF) 53 3-7-4均方和(Mean of Square；MS) 53 3-7-5變異比(Variance Ratio；F) 53 3-7-6純變動(Net variation) 54 3-7-7因子貢獻率(Percentage of Contribution, PC) 54 第四章 實驗步驟與方法 58 4-1 實驗方法 58 4-2 實驗試件之簡介及特性 59 4-3 實驗設備 60 4-3-1500瓦單模光纖雷射(Yb:fiber laser) 60 4-3-2三維表面微細形貌量測儀 61 4-3-3掃描式電子顯微鏡(SEM) 62 4-3-4X光繞射儀(X-ray Diffractometer, XRD) 62 4-3-5奈米壓痕試驗機(Nano Indenter) 63 4-3-6雙束型聚焦離子束(FIB) 63 4-3-7往復式磨耗試驗機 64 4-4 實驗流程 65 4-4-1試件準備 65 4-4-2拋光實驗 65 4-4-3表面形貌分析 66 4-4-4微結構檢測 68 第五章 理論模型建立 76 5-1 Comsol物理多耦合軟體簡介 76 5-2 方程式 76 5-3 模型幾何及網格分佈 77 5-4 模擬假設 78 5-5 邊界、初始條件 78 第六章 結果與討論 82 6-1 雷射拋光實驗 82 6-1-1第一階段─田口實驗設計 82 6-1-2第二階段─全因子實驗 85 6-1-3第三階段─重要因子水準改變實驗 85 6-2 表面形貌分析 86 6-2-1表面粗糙度量測結果之分析 86 6-2-2SEM表面形貌觀察 87 6-2-3空間傅立葉分析 87 6-2-4臨界頻率分析 89 6-2-5材料承壓比分析 89 6-2-6轉移函數分析 90 6-3 微結構分析 92 6-3-1X光繞射分析 92 6-3-2改質層厚度分析 92 6-3-3硬度與彈性模數分析 93 6-3-4磨耗性質分析 94 6-4 模擬結果 95 第七章 結論與未來展望 138 7-1 結論 138 7-2 未來展望 139 參考文獻 140 自述 152

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