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研究生: 林宸緯
Lin, Chen-Wei
論文名稱: 考量切削狀態變化之2.5D CNC 銑削加工效率與比能耗最佳化研究
Optimization of Machining Efficiency and Specific Energy Consumption for 2.5D CNC Milling Considering Cutting State Variations
指導教授: 歐峯銘
Ou, Feng-Ming
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: 2026
畢業學年度: 115
語文別: 中文
論文頁數: 109
中文關鍵詞: CNC工具機 、NC Code 、多目標最佳化 、加工時間 、比能耗 、NSGA-II
外文關鍵詞: CNC machine tool, NC Code, multi-objective optimization, machining time, specific cutting energy, NSGA-II
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  • CNC 工具機廣泛應用於精密製造產業,加工過程中之能源消耗直接影響製造成本與碳排放,如何兼顧加工效率與能源效益已成為智慧製造之核心課題。既有CNC加工能耗相關研究已從切削參數建模、NC Code解析至製程方案最佳化等面向取得豐碩成果。在此基礎上,本研究進一步將加工過程中切削寬度與切削深度隨工件幾何與殘料分布變化之特性納入考量,建構一套從CAM規劃端出發之多目標最佳化框架,以最小化總加工時間(Ttotal)與比能耗(SECtotal)為雙目標,於加工前即取得兼顧效率與能源效益之加工參數設定。
    本研究以NX CAM軟體中可調控之刀具路徑策略、刀路間距、每刀切削深度、每齒進給量與主軸轉速等五項加工參數作為決策變數。在能耗評估方面,透過解析NC Code將刀具路徑離散化為多個步距,並以體素切削模擬逐段提取各刀具位置之切削寬度與切削深度,據此計算切削功率與能耗;切削附加功率模型則由L27切削實驗建立,以切削寬度、切削深度、每齒進給量與主軸轉速作為輸入變數。在最佳化求解方面,採用非支配排序基因演算法(NSGA-II)搜尋Pareto解集合,並透過理想點決策法選取折衷解。
    驗證實驗採用兩款涵蓋口袋、外輪廓與階梯等2.5D特徵之驗證工件進行實機切削驗證。折衷解之模型推估值與實測值之Ttotal 與 SECtotal誤差皆小於4%。在製程改善方面,折衷解於部分基準組對照中實現兩項目標之同時改善,最高可達Ttotal縮短58.8% 且SECtotal降低23.6%。結果顯示,本研究方法可有效反映加工過程中切削狀態之動態變化,並透過多目標最佳化於參數空間中找到兼顧加工時間與比能耗之組合,可作為加工前製程參數決策之參考。

    CNC machine tools are widely used in precision manufacturing, where energy consumption directly affects manufacturing costs and carbon emissions. Existing research has achieved substantial results in cutting parameter modeling, NC Code parsing, and process-level optimization. Building upon these foundations, this study further incorporates the dynamic variations of cutting width and cutting depth caused by workpiece geometry and residual material distribution, and constructs a multi-objective optimization framework from the CAM planning stage to minimize total machining time (Ttotal) and specific cutting energy (SECtotal) simultaneously.
    Five machining parameters in NX CAM are employed as decision variables: cutting pattern, stepover, depth of cut per layer, feed per tooth, and spindle speed. Tool paths are discretized into multiple steps by parsing NC Code, and voxel-based material removal simulation extracts cutting width and cutting depth at each tool position for power and energy calculation. The cutting-induced additional power model is established through L27 experiments with cutting width, cutting depth, feed per tooth, and spindle speed as inputs. NSGA-II is employed to search for the Pareto solution set, and the ideal point method selects the compromise solution.
    Validation was conducted using two workpieces encompassing 2.5D features such as pockets, peripheral profiles, and steps. Prediction errors of both Ttotal and SECtotal for the compromise solutions were less than 4%. The compromise solutions achieved simultaneous improvement in both objectives under certain baseline comparisons, with reductions of up to 58.8% in Ttotal and 23.6% in SECtotal. Results demonstrate that the proposed method effectively captures dynamic cutting condition variations and identifies parameter combinations balancing machining time and specific cutting energy.

    摘要 I Abstract II 致謝 VII 目錄 VIII 圖目錄 XI 表目錄 XIV 參數符號對照表 XV 第一章 前言 1 1-1 研究背景 1 1-2 文獻回顧 1 1-2-1 工具機能耗預測 2 1-2-2 工具機能耗最佳化 9 1-3 研究動機與目的 14 1-4 論文架構 16 第二章 加工情境與研究範圍 19 2-1 加工情境界定 20 2-1-1 加工特徵與粗加工階段 21 2-1-2 加工設備與機台規格 21 2-2 規劃端加工參數與執行端切削參數定義 22 2-2-1 加工參數定義 22 2-2-2 切削參數定義 25 2-3 加工過程中之切削寬度與切削深度變化 26 2-4 加工效率與切削能源效益之權衡關係 29 2-5 研究範圍、假設與限制 31 第三章 研究方法 33 3-1 NC Code解析與能耗預測 35 3-1-1 NC Code前處理 35 3-1-2 切削參數提取與執行時間計算 36 3-1-3 功率模型與切削能耗計算 39 3-2 最佳化目標函數定義與計算 41 3-3 最佳化模型建構 42 3-3-1 決策變數與適應度函數 42 3-3-2 限制條件 43 3-4 非支配排序基因演算法(NSGA-II) 46 3-5 折衷解之決策方法 52 第四章 實驗架構、能耗模型與驗證設計 54 4-1 量測系統架構 54 4-2 切削能耗量測與模型建立 55 4-2-1 切削能耗量測與SECtotal計算方法 55 4-2-2 切削能耗預測模型 57 4-3 驗證工件 59 4-4 實驗對照策略與評估指標 61 4-4-1 實驗對照策略 61 4-4-2 評估指標定義 62 4-5 體素模擬之參數設定 62 第五章 最佳化結果分析與探討 64 5-1 演算法收斂性分析與Pareto front分布探討 64 5-2 最佳化決策驗證 68 5-3 製程改善評估 69 5-3-1 W1之改善效益分析 69 5-3-2 W2之改善效益分析 75 第六章 結論與建議 83 6-1 結論 83 6-2 建議與未來改善 85 參考文獻 87

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