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研究生： 許文哲
Xu, Wen-Zhe
論文名稱： 外圓磨削過程之振動機制及再生顫振穩定性分析
Analysis of Grinding Vibration Mechanism and Regenerative Chatter Stability in Cylindrical Grinding Process
指導教授： 陳朝光
Chen, Cha’o-Kuang
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： 2018
畢業學年度： 106
語文別： 中文
論文頁數： 209
中文關鍵詞： 動態外圓磨削力 、再生顫振 、幾何卜瓦松隨機過程 、尺寸效應 、撓度
外文關鍵詞： dynamic external cylindrical grinding force, regenerative chatter, geometric Poisson random process, size effect, deflection
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    • 隨著工業蓬勃發展，產品零件所需要之精度亦日益上升，做為工件加工最後一道工序之磨削精加工，是控制精度與成品表面品質最重要製程，因此需要建立一套完整的磨削過程振動機制，找出磨削振動根源，用以改善振動問題，進而提升工件之品質。然而砂輪表面磨刃分佈具有隨機性質導致振動機制較其他加工方式複雜，因此本文將以機率統計之概念導入，建立一套統合隨機動態外圓磨削力、機台結構動態撓性之動態磨削系統，進而掌握磨削過程整體振動型態及特徵。後續先將工件磨削之再生性納入考量，再把圓柱體工件視為尤拉樑之彈性體而具有撓度，最終統整出一套外圓磨削振動系統。
    砂輪表面磨刃數分佈為一個隨機過程，所以本文將以幾何卜瓦松分佈特徵進行擬合，並以文獻實驗加以驗證磨刃數目分佈具有幾何卜瓦松隨機過程所有性質，並根據統計原理建立具有隨機特性之磨削系統。
    由於工件磨削具有再生之特性，導致磨削加工過程中會發生再生顫振，使得工件精度大打折扣，因此需要計算磨削之穩定邊界使加工免於磨削顫振困擾。然而再生顫振並非在固定某些磨削條件區域下必定發生之事件，而是有機率性得產生，因此本文將以機率分佈詮釋再生顫振主要發生區域，並對區域外之磨削條件給予風險評估，並於分析中加入了尺寸效應之影響，使得理論更加完整。
    以高速磨削、緩進給磨削、不使用頂心磨削與使用頂心磨削等磨削方式做為例子，驗證這些磨削方式對於振動之影響與現實加工實驗相符，說明磨削參數經過合理設計與調整，便可有效降低磨削振動量並提升穩定性，也證實本文磨削系統之正確性。

    This paper presents the external cylindrical grinding force model with dynamic properties. In the past studies, the external grinding force was assumed to be a gain constant, and the vibration system did not contain the dynamic characteristics of the external grinding force. However, the dynamic nature of the external cylindrical grinding force affect the grinding vibration. This paper assumes that the grit distribution of the wheel surface is a geometric Poisson random process. The dynamic model of the external cylindrical grinding force is then established using the external cylindrical grinding geometry and the grit distribution.

    This dynamic model is then combined with the dynamic compliance of the machine structure, the workpiece regenerative character, the size effect, the deformation of the workpiece to establish the external cylindrical plunge grinding vibration system. In the past studies, the workpiece regenerative chatter is a fixed critical stability boundary. This paper presents a "probability critical stability boundary" to explain the random occurrence of regenerative chatter.

    摘要 I Extended Abstract III 誌謝 X 目錄 XI 表目錄 XVI 圖目錄 XVII 符號說明 XXIV 第一章 緒論 1 1-1 前言 1 1-2 研究動機與目的 2 1-3 文獻回顧 4 1-3-1 磨削力與振動機制及系統建立相關研究 5 1-3-2 再生顫振機制建立相關研究 8 1-4 本文架構 10 第二章 動態磨削力之建模與驗證 16 2-1 基本磨削幾何理論 16 2-1-1 砂輪之表面形態 16 2-1-2 磨削切屑幾何 17 2-1-3 比磨削能 21 2-2 動態磨削力模式之建立 22 2-2-1 磨削座標系統 22 2-2-2 單一磨刃之磨削力推導 23 2-2-3 磨刃密度函數 27 2-2-4 建立動態磨削力之模式 36 2-3 動態磨削力模式功率強度頻譜分析 39 2-3-1 基本磨削函數之能量密度頻譜分析 40 2-3-2 磨刃密度函數之功率密度頻譜分析 41 2-4 磨削常數之判認 43 2-4-1 磨削能與比磨削能 43 2-4-2 磨刃分散常數之判認 45 2-5 文獻驗證及討論 47 2-5-1 基本磨削函數正確性之驗證 49 2-5-2 磨刃密度分佈驗證與磨削條件對磨削力影響之探討 54 2-6 結語 60 第三章 平面磨削振動建模 86 3-1 磨削力對徑向磨削寬度線性化推導 86 3-2 平面磨削強迫振動系統之建立 91 3-3 平面磨削振動系統驗證及討論 92 3-3-1 平面磨削振動系統之驗證 93 3-3-2 文獻實驗與系統模擬磨削振動差異性分析 98 3-3-3 結構撓性對磨削力影響之分析 100 3-4 結語 102 第四章 外圓磨削之再生顫振穩定性分析 115 4-1 外圓磨削振動系統建模 115 4-1-1 外圓磨削振動系統之建立 115 4-1-2 外圓磨削系統驗證及討論 117 4-1-3 磨削條件對外圓磨削振動之影響 121 4-2 穩定性分析 127 4-2-1 尺寸效應 128 4-2-2 外圓磨削再生顫振穩定性之分析 131 4-2-3 結果及討論 134 4-3 結語 139 第五章 外圓磨削考慮工件撓度之再生顫振穩定性分析 160 5-1 外圓工件撓度之振動分析 160 5-1-1 工件徑向振動之振動分析 160 5-1-2 工件徑向振動之自由振動分析 162 5-1-3 不使用頂心下工件徑向振動之自由振動分析 164 5-1-4 使用頂心下工件徑向振動之自由振動分析 172 5-1-5 工件徑向振動之強制振動分析 176 5-2 考慮工件撓度之外圓磨削振動系統建模與穩定性分析 179 5-3 系統穩定性結果及討論 186 5-4 結語 190 第六章 結論與建議 200 6-1 結論 200 6-2 未來研究方向與建議 203 文獻參考 205

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