銑削具有加工高精度複雜形狀工件之能力，廣泛應用於精密製造領域。但其會在工件表面產生殘留應力，導致變形影響工件品質如板件之平面度，因而限制了其使用範圍與機台能力。本論文經由實驗設計及平面度分析，探討如何在符合板件平面度要求下獲得最大材料移除率之銑削加工參數。首先求取在夾具及主軸功率扭矩及轉速限制條件下可實行之銑削加工參數範圍，接著進行響應曲面法之實驗設計，將直交表融入Box-Behnken方法，以較有效率之實驗數量分析銑削參數(轉速、軸向切深與每刃進給)對平面度之影響，並建立平面度之模型。實驗發現製程變異對平面度預測準確性影響甚大，故本文將製程變異納入模型中，以利實際生產製造中求得最大材料移除率之加工參數。實驗分析結果發現高轉速、低每刃進給以及低軸向切深可得較好的板件平面度，而其中以軸向切深影響平面度最劇烈。最後以所建立之具製程變異的平面度模型，成功獲得符合平面度要求之最大材料移除率的銑削參數。

Milling can achieve complex geometry and high surface quality part. Therefore, milling is widely utilized in precision manufacturing industry. However, milling induces residual stress and deformation, resulting in poor quality parts, such as the flatness of plate. In this article, systematic method of experiment design is used to analyze the influence of flatness on plate and to establish a model of flatness in milling. The model is used to find maximum material removal rate under the constraint of flatness. First, we utilize the cutting coefficients and convolution milling force model to find the milling parameters under the limit of vacuum chuck and spindle. Then, we use response surface methodology and combination of orthogonal array (L9) and Box-Behnken design in order to analyze milling parameter of flatness and obtain an accurate model of flatness with efficient number of experiments. Also, the flatness model considers process variation due to the fact that it is more efficient for industry. The result of experiment showed that high speed, low feed per tooth and low depth of cut constitute the key parameters for better flatness. Finally, we use the derived flatness model incorporating process variation effect to find the optimal process parameters to achieve the maximum material removal rate under the constraint of flatness.

Alauddin, M., M. A. El Baradie, and M. S. J. Hashmi. "Computer-aided analysis of a surface-roughness model for end milling," Journal of Materials Processing Technology 55.2, pp. 123-127, 1995.
Bagci, Eyup, and Şeref Aykut. "A study of Taguchi optimization method for identifying optimum surface roughness in CNC face milling of cobalt-based alloy (stellite 6) , " The International Journal of Advanced Manufacturing Technology 29.9-10, pp. 940-947, 2006
Bouzid Saı̈, W., N. Ben Salah, and J. L. Lebrun. "Influence of machining by finishing milling on surface characteristics. ," International Journal of Machine Tools and Manufacture 41.3, pp. 443-450, 2010
Denkena, B., D. Boehnke, and L. De Leon. "Machining induced residual stress in structural aluminum parts," Production Engineering 2.3, pp. 247-235, 2008
El-Axir, M. H. "A method of modeling residual stress distribution in turning for different materials," International Journal of Machine Tools and Manufacture 42.9, pp. 1055-1063, 2002
Fuh, Kuang-Hua, and Hung-Yen Chang. "An accuracy model for the peripheral milling of aluminum alloys using response surface design," Journal of materials processing technology 72.1 , pp. 42-47, 1997
Ghani, J. A., I. A. Choudhury, and H. H. Hassan. "Application of Taguchi method in the optimization of end milling parameters," Journal of Materials Processing Technology 145.1, pp. 84-92, 2004
Jeelani, S., S. Biswas, and R. Natarajan. "Effect of cutting speed and tool rake angle on residual stress distribution in machining 2024-T351 aluminium alloy—unlubricated conditions," Journal of materials science 21.8, pp. 2705-2710, 1986
Koenigsberger, F., and Sabberwal, A. J. P. "An Investigation into the Cutting Force Pulsations During Milling Operations," International Journal of Machine Tool Design and Research 1, pp.15-33, 1961
Krishankant, Jatin Taneja, Mohit Bector, Rajesh Kumar. "Application of Taguchi Method for Optimizing Turning Process by the effects of Machining Parameters," International Journal of Engineering and Advanced Technology 2, pp. 263-274.,2012
Kwak, Jae-Seob. "Application of Taguchi and response surface methodologies for geometric error in surface grinding process," International Journal of Machine Tools and Manufacture 45.3, pp. 327-334, 2005
Liu, Z., Xu, J., Han, S., Chen, M. "A coupling method of response surfaces (CRSM) for cutting parameters optimization in machining titanium alloy under minimum quantity lubrication (MQL) condition," International Journal of Precision Engineering and Manufacturing 14.5, pp. 693-702, 2013
Logothetis, N., and A. Haigh. "Characterizing and optimizing multi‐response processes by the taguchi method," Quality and Reliability Engineering International 4.2, pp. 159-169, 1988
M’saoubi, R., Outeiro, J. C. "Residual stress analysis in orthogonal machining of standard and resulfurized AISI 316L steels," Journal of materials processing technology96.1, pp. 225-233, 1999
Martellotti, M. E. "An Analysis of the Milling Process, Part 2: Down Milling," Transaction of ASME, Vol. 67, pp. 233-251, 1945
Martellotti, M. E. "An Analysis of the Milling Process," Transaction of ASME, Vol. 63, pp.677-700, 1941
Melkote, S. N.and Endres W. J. "The Importance of Including Size Effect When Modeling Slot Milling," ASME Journal of Manufacturing Science and Engineering 120, pp. 69-75, 1988
Nalbant, M., H. Gökkaya, and G. Sur. "Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning," Materials & design 28.4, pp. 1379-1385, 2007
Öktem, H., T. Erzurumlu, and H. Kurtaran. "Application of response surface methodology in the optimization of cutting conditions for surface roughness," Journal of Materials Processing Technology 170.1 , pp. 11-16, 2005
Pai. D. , Rao S., Shetty R. "Application of Taguchi and Response Surface Methodologies for Metal Removal Rate and Surface Roughness in Grinding of Drac’s," International Journal of Engineering and Management Sciences 3, pp. 1-8.,2012
Palanikumar, K. "Application of Taguchi and response surface methodologies for surface roughness in machining glass fiber reinforced plastics by PCD tooling," The International Journal of Advanced Manufacturing Technology 36.1-2, pp. 19-27, 2008
Routara, B. C., A. Bandyopadhyay, and P. Sahoo. "Roughness modeling and optimization in CNC end milling using response surface method: effect of workpiece material variation," The International Journal of Advanced Manufacturing Technology 40.11-12, pp. 1166-1180, 2009
Sabberwal, A. J. P. “Chip Section and Cutting Force During the Milling Operation," Annals of the CIRP 10, pp. 197-203., 1961
Salio, M., T. Berruti, and G. De Poli. "Prediction of residual stress distribution after turning in turbine disks," International journal of mechanical sciences 48.9, pp. 976-984, 2006
Shaji, S., and V. Radhakrishnan. "Analysis of process parameters in surface grinding with graphite as lubricant based on the Taguchi method," Journal of Materials Processing Technology 141.1, pp. 51-59, 2003
Sridhar, B. R., Devananda, G., Ramachandra, K., Bhat, R. "Effect of machining parameters and heat treatment on the residual stress distribution in titanium alloy IMI-834," Journal of Materials Processing Technology 139.1 ,pp. 628-634, 2003
Thamizhmanii, S., S. Saparudin, and S. Hasan. "Analyses of surface roughness by turning process using Taguchi method," Journal of Achievements in Materials and Manufacturing Engineering 20.1-2, pp. 503-506, 2007
Wang, J. J. "Convolution Modeling of Milling Force System and Its Application to Cutter Runout Identification," ph.D.thesis, School of Mechanical Engineering, Georgia Institute of Technology, April., 1992
Wang, J. J. J., Liang, S. Y., Book, W. J. "Convolution analysis of milling force pulsation," Journal of engineering for industry 116.1, pp. 17-52, 1994
Wang, M. Y., Chang, H. Y. "Experimental study of surface roughness in slot end milling," International Journal of Machine Tools & Manufacture 44, pp.51-57., 2004
Yang, W. H., and Y. S. Tarng. "Design optimization of cutting parameters for turning operations based on the Taguchi method," Journal of Materials Processing Technology 84.1, pp. 122-129, 1998
Zhang, Julie Z., Joseph C. Chen, and E. Daniel Kirby. "Surface roughness optimization in an end-milling operation using the Taguchi design method," Journal of Materials Processing Technology 184.1 , pp. 233-239, 2007
Zhang, S., T. C. Ding, and J. F. Li. "Determination of surface and in-depth residual stress distributions induced by hard milling of H13 steel," Production Engineering 6.4-5, pp. 375-383, 2012
李輝煌，田口方法-品質設計的原理與實務，高立圖書有限公司，2012
葉怡成，高等實驗計畫法，五南圖書出版股份有限公司，頁66~265，2009
黎正中，穩健設計之品質工程，台北圖書有限公司，1993
黎正中，實驗設計與分析，高力圖書有限公司，頁13-1~14-88，1998