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研究生： 沈芳呈
Shen, Fang-Cheng
論文名稱： 五軸球頭銑刀加工模擬與應用智慧刀把於切削力預測分析薄工件變形
Process Modeling and Cutting Force Prediction with Sensory Tool Holder in Five-axis Ball-end Milling of Thin-walled Parts
指導教授： 黃聖杰
Hwang, Sheng-Jye
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： 2021
畢業學年度： 109
語文別： 中文
論文頁數： 100
中文關鍵詞： 薄工件 、彈性變形 、材料移除 、切削力模型 、誤差補償
外文關鍵詞： thin workpiece, elastic deformation, error compensation, material removal, cutting force model
相關次數： 點閱：130  下載：0 
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    • 在五軸銑床加工中，工件承受刀具移除材料的切削力，其中薄工件容易因低剛度而產生彈性變形進而產生體積誤差。一般傳統實務上透過優化切削參數降低切削力、改變工法路徑或機上量測補償以改善此問題，但是，這些方法需要額外的加工時間成本，也無法瞭解背後機制。
    文獻中已經發展過許多材料移除演算法，搭配切削力學模型就能預測在五軸銑床製程中施加於工件之瞬時切削力，甚至能考慮到切削過程中工件的剛度變化，對加工中工件進行有限元素分析，以預測製程中工件變形。但是，現行缺乏研究從選定材料、刀具、機台開始，進行以下分析程序: 建構切削力學模型，執行材料移除演算法，再進行變形分析，最後依據變形量對薄壁工件做補償。
    本文建立一套系統分析以球銑刀執行五軸加工中之工件變形。首先，以智慧刀把執行切削試驗，分析數據求得該材料-刀具之切削力模型。再來，將CAM軟體中預先設置好的工件模型、胚料模型、刀具路徑匯入系統計算材料移除，求得切削點的加工中工件模型與刀具工件接觸情形。第三，以Finite cell method進行準靜態分析以求得每個切削點之加工中工件變形。最後，擬合出製程中產生的連續變形並輸出補償刀具路徑結果。
    由結果可以看出，依據變形量補償刀具路徑確實可以得到更小的加工誤差，但是補償的方法設計還有許多發展的空間，如何更精準的補償誤差是下一個有趣的挑戰。

    Cutting force-induced error is crucial for improving the final quality of thin-walled workpieces in machining. The conventional solution for the deformation of in-process workpieces is to apply a multi-pass process to reduce the cutting forces, leading to poor machining efficiency. This study presents a tool path compensation method according to the elastic deformation of in-process workpieces to ensure machining accuracy and process efficiency.
    This article analyzes the elasticity of the thin workpiece in the five-axis milling machine processing process, which is affected by the cutting force, and the processing error is analyzed. First, conduct cutting constant experiments, establish a five-axis ball milling cutter cutting force prediction model, perform a material removal algorithm based on the voxel model to simulate the stiffness change of the workpiece during processing. Last, calculate the contact between the tool and the workpiece to bring in The cutting force model predicts the cutting force. Perform a quasi-static finite element analysis on the workpiece, the contact situation, and the cutting force obtained during the processing to predict the deformation of the workpiece. Finally, create the error fitting function to indicate the compensation amount of the cutting point, and the CL file is compensated for the position of the tooltip point, and the thin-wall cutting experiment is verified.

    摘要 I Extended Abstract II 致謝 XIII 目錄 XIV 表目錄 XVII 圖目錄 XVIII 符號說明 XXI 第一章 緒論 1 1.1 前言 1 1.2 文獻回顧 3 1.2.1 加工誤差與薄件加工 3 1.2.2 切削力學 5 1.2.3 CWE與材料移除 6 1.2.4 變形預測 9 1.3 研究動機與目的 14 1.4 論文架構 15 第二章 基礎理論 16 2.1 球銑刀銑削模式 16 2.1.1 犁切力的成因與影響 16 2.1.2 球銑刀座標系統 18 2.1.3 局部切削力 20 2.1.4 總切削力 23 2.1.5 切削常數實驗 24 2.1.6 切削常數之表示 26 2.2 Finite Cell Method 27 2.2.1 基本概念 27 2.2.2 定義問題 30 2.2.3 建立網格 32 第三章 研究方法 34 3.1 研究流程 36 3.2 智慧刀把 37 3.2.1 設備介紹 37 3.2.2 數據處理 39 3.3 材料移除 41 3.3.1 體素模型 42 3.3.2 材料移除 43 3.4 IPW更新 50 3.5 計算CWE 51 3.6 切削力預測 53 3.6.1 刀具模型 53 3.6.2 切削點 54 3.6.3 切削力計算 57 3.7 FCMlab Toolbox 59 3.7.1 系統架構與使用方式 59 3.7.2 邊界條件 61 3.8 誤差補償 63 3.9 系統架構 67 3.9.1 物件導向程式設計 67 3.9.2 設計模式 67 第四章 分析與實驗結果 70 4.1 實驗設備 70 4.2 切削實例 73 4.2.1 切削實驗結果 73 4.2.2 切削實驗工件模型 77 4.2.3 材料移除結果 78 4.2.4 FCM分析結果 80 4.2.5 補償與量測結果 81 第五章 結論與未來展望 89 5.1 結論 89 5.2 討論與未來展望 91 參考資料 95 索引 99

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