雙面負角銑刀片是未來捨棄式銑刀片發展的一大趨勢，雙倍刀刃數具經濟上的優勢，刀刃強度佳不易崩壞，負角切削造成較大的軸向切削力，對加工表面完整性及加工穩定性皆有正面影響，但其較大的切削力，將縮短刀具壽命。切削係數是預測銑削力的重要參數，因此本文以切削係數作為設計目標，針對面銑加工用負角銑刀片進行刃口幾何設計之研究。為減少實驗的時間與成本，使用有限元素分析軟體來模擬切削情形，利用田口方法，探討刃口幾何對切削係數的影響。並運用反應曲面法中的Box-Behnken設計，建立以進給、軸向切深與刃口幾何參數對切削係數的二階迴歸模型，再以基因演算法求取特定切削條件下的理想幾何參數，最後進行模擬與實際切削的差異比較，並驗證田口方法所分析的趨勢與迴歸模型之可靠度。模擬分析與驗證實驗的結果顯示，進給量對比切削係數有顯著的影響，進給量愈大比切削係數愈小。而在刃口幾何設計參數中，選擇較大的刃寬有助於比切削係數的減少，前傾角對比切削係數的貢獻度較大其次是刃寬，前傾角增加也有助於比切削係數之減小，但有一範圍限制。本文亦提供圓形銑刀片切屑負載之幾何分析，圓形刀片的實際切屑厚度為刀具旋轉角度、刀片半徑、軸向切深及進給量之函數。

This thesis investigates the effect of insert edge geometry on cutting coefficients in face milling. There are many advantages of negative cutting insert: stronger strength of edge, better stability, higher feed rate, and more economical because of its double blades. But large cutting force and high temperature which cannot be ignored decrease tool life. To improve these shortcomings, the design of edge geometry is the key factor. Cutting coefficients are important parameters to predict cutting forces. Therefore, Taguchi method is applied to analyze the contribution to cutting coefficient of each geometric parameter. Response surface methodology is used to establish a model for cutting coefficient evaluating by cutting depth, feed rate, and edge geometry. The result of this study shows that feed rate has the greatest contribution to cutting coefficient, and cutting edge with larger land angle and blade width is more effective. The results were verified by finite element simulation and cutting experiments. This paper also provide a chip geometry load analysis of round milling insert, the actual chip thickness is expressed by the insert radius, tool rotational angle, insert rotational angle, cutting depth, and feed rate.

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