本文探討弦波式鋸條鋸削製程之分析。目前尚未有研究團隊對弦波式鋸條鋸削製程中齒刃之切屑負載做深入分析，因此於鋸削加工時，無法得知鋸條中每個齒刃對材料移除的貢獻度。若能取得鋸條中每個齒刃之切屑負載，即可預測鋸條鋸削時優先失效之齒刃位置。透過鋸條齒刃切屑負載公式之建立，配合實驗所得之比切削係數，可有效解析弦波式鋸條之鋸削製程，並達到預測鋸條鋸削工件之結果。
本論文切屑負載之計算使用二種方法。第一種：推導公式，首先定義弦波式鋸條幾何參數，假設鋸削時每刃進給為定值，齒刃位移有等相位，則可推導鋸條齒刃切屑負載公式；此方法計算快速，但只限於齒刃位移有等相位為前提。第二種：軟體模擬，先測量鋸條齒刃的幾何參數，再將參數透過軟體模擬出工件被弦波式鋸條鋸削移除之情形，並計算出每個齒刃切屑負載；此方法須先測量鋸條齒刃之幾何參數且耗時，但齒刃位移可不受等相位條件限制。經計算後得知弦波式鋸條在弦波波谷位置之前一個齒刃有最大切屑負載，可推測此齒刃為鋸條鋸削時優先失效之齒刃。
弦波式鋸條之單一弦波有多個齒刃並呈弦波式排列。本研究選擇鋁合金AA6061-T651為切削工件，考慮以銑削工具機模擬鋸切運動行為，將鋸條研磨成不同齒刃數，做不同切削進給之切削實驗，並根據三維動力計量測判讀之結果，可取得比切削係數。最後以手弓鋸鋸切而驗證推導之鋸削模式，結果誤差約在20%。

This paper analyzes sawing process for wave-type hack saw blades. At present, there is none of research team assaying saw blade’s chip load of sawing process for wave-type hack saw blades. For this reason, the contribution for material detachment of each blade can not be known when sawing. If getting each blade’s chip load, it will be possible to forecast the first expiration blade. By establishing formula for chip load and cooperating with specific coefficients, sawing process for wave-type hack saw blades can be effectively analyzed and reach the goal in forecasting the result of the saw blade truncating work piece.
In this paper, calculate chip load by two ways. The first way, derive formula. First, make definition of wave-type hack saw blade’s geometric parameter, suppose each edge to feed is definite value and displacement of blade is equal. Then, formula of saw blade’s chip load can be derived. This way is quick for calculating, but it’s based on the premise that overlap of blade has the order. The second way, simulate by soft ware. Survey saw blade’s geometric parameter advance, which be simulated by soft ware to get circumstances of work piece detachment that sawed by wave-type hack saw blades, and calculate each blade’s chip load. This way is time-consuming and must survey saw blade’s geometric parameter advance, but overlap of blade is not be limitative. As a result by calculating, the preceding blade in wave trough of wave-type hack saw blades has the maximum of chip load. Therefore, the blade can be broken as the first expiration one.
A wave-type of hack saw comprises many teeth, ranked as the sine wave. The work piece is a rectangular of Aluminum alloy AA6061-T651 of this study. Considering of simulating sawing model by milling machine, choose the wave-type hack saw blades and grind different tooth used grinding machine, different feed per tooth for experiment. A dynamometer is mounted on the table of the machine. The three directional cutting force signals from the dynamometer are collected by the computer through the A/D converter. According to three directional cutting force and cutting area, specific coefficients can be obtained. Finally, use the hack saw to cut work piece by hand to prove the cutting force model, the error is about 20%.

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