薄壁管狀形工件常應用在許多航太及醫療的產品上，然而由於其特殊的幾何形狀與低加工性，在銑切這類零件時，刀具與工件受到切削力容易產生形變甚至毀損，進而影響加工精度。因此，在不大幅度影響產能的前提下，找出適當的切削條件，克服加工難度變得十分重要。
首先，本文研究薄壁管狀形工件的切削動態包括銑切振動與形變量。不穩定的振動，例如顫振(chatter)，會嚴重影響加工品質，且降低主軸與刀具壽命。在解決方法上，可以藉由穩定耳垂圖(stability lobes diagram)找出適當的切削條件。對於形變量的動態特性，本文透過有限元素分析軟體ANSYS模擬刀具與工件受力形變，由結果可以建立切削力、形變量與刀具位置的三者關係數學模型。
其次，根據文獻研究顯示切向力占總切削力極大的部分，而切向力可以從切削扭矩中此項中，經演算粹取而推倒獲得，因此本文建立針對管狀形薄壁零件的平均切削扭矩模型，可以發現進給率與切削深度直接影響加工精度與生產效率。
接著從此模型中，本文提出一套切削扭矩迴授控制理論，透過主軸馬達電流去估測當時的切削扭矩，並利用卡爾曼濾波器(Kalman filter)去除訊號中的雜訊。在允許的表面誤差範圍內，適應性調整最大軸向進給率。透過銑切動態的研究，切削扭矩目標值應隨著刀具位置的改變，進行適當的調整。
最後，為了驗證控制器的效益，本文重新設置電腦數值控制(computer numerical control)的運作程序，在銑切中也能達成進給率即時調控。實驗主要針對直筒管狀形與錐形工件進行螺旋銑切，並比較具備與移除自調切削扭矩目標值的控制器，結果顯示本文提出的控制策略在加工精度與生產效率間取得最佳切削條件。

Thin-wall tubular-geometry workpiece have been widely applied in aircraft and medical industries. However, due to the special shape of this kind of workpiece and induced poor machinability, the desired accuracy of machining tends to be greatly degraded, no matter what metal-cutting task, such as milling, drilling or turning, is undertaken. Therefore, this research proposes a few suitable cutting conditions which are able to prevent break/crack of thin-wall workpiece but almost retain the same productivity. To achieve this goal, a systematic study on surface profile of machined parts due to deflections caused by both tool and workpiece is presented. In addition, an effective feedback control system is proposed by this thesis for applying appropriate cutting force to account for severe deflection of tool/workpiece and potential break/crack of the thin-wall conical pipes. The experiment mainly focus on machining of thin-walled straight tubular and conical tubular geometries components by helical milling, and the results demonstrate that the proposed control strategy provides an optimal cutting conditions between accuracy and machining cycle time.

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