加工效率與工具機精度為加工系統中影響產品尺寸精度與品質重要的兩個因素，本論文首先分析工具機誤差分佈特性對產品的影響，接著分析傳統銑削加工製程與放電加工製程中因加工參數變化而產生的製程誤差對產品尺寸誤差之影響。本文中各誤差項之量值由量測平均值表示，誤差之分佈特性則由量測變異與標準差描述之，結合誤差傳遞理論與統計機率分佈理論，分析產品尺寸誤差與各誤差源之關聯性，並針對個別加工製程提出適當之加工參數與加工策略。
在工具機誤差方面，一般工具機在溫度與濕度控制條件下，幾何空間誤差為工具機誤差的主要來源，本文以向量法為基礎，在不考慮微小角度誤差影響之前提下，建立不同構型之三軸工具機空間誤差數學模型，配合雷射干涉儀與空間對角線量測方法量測之真實誤差結果，建構工具機空間之誤差分佈地圖。
在製程誤差方面，本文選擇非傳統加工之放電加工製程與傳統銑削製程為舞台，分別探討各製程特性與加工參數對產品尺寸誤差的影響。在放電加工系統中，本文以放電坑側邊與底部放電間隙為觀察目標，除了分析探討電極消耗、電極尺寸、工具機定位精度與加工件尺寸在不同加工條件下彼此互相影響之結果外，更進一步分析與放電間隙相關之誤差項之交互作用，建立放電間隙之變異模式。在銑削加工系統中，本文以受力後刀具變形為製程誤差主要來源，探討不同加工條件之切削力、刀具幾何、刀具偏擺在不同構型工具機上對加工件尺寸誤差及其變異之影響，分析加工系統中各誤差項之權重。
在銑削加工系統中，切削深度的改變將導致不同型態的折曲表面輪廓出現於加工面上，此折曲表面輪廓特徵由(Kline, 1984)發現後，至今經過約30年的時間，所有研究仍皆視此折曲表面為複雜且必然之切削結果，本文以銑削捲積力模式為基礎，首次藉由分析屑寬密度函數與基本切削函數之捲積過程探討銑削加工中折曲表面輪廓之形成機制，分析由軸向切深、徑向切深與刃數定義之軸向浸入角、徑向浸入角與刀刃間距之交互作用，將交互作用分為四大類後再依序探討不同交互作用影響下之折曲表面輪廓生成機制。透過本文定義之力矩密度函數，完成切削力量、切削力矩與等效切削力中心之角度域解析模式，再者，任一切削高度之表面誤差與切削力之對應關係可透過本文首度定義之表面生成窗函數加以描述。最後將折曲表面輪廓定義為三個形態，並完成各形態折曲點高度位置之閉合解析模式，研究結果發現，各型態折曲點高度位置只由六個參數即可決定，其中三個為刀具幾何：直徑、螺旋角及刃數，三個為切削參數：軸向切深、徑向切深與徑向比切削係數。本文進一步將此六個參數無因次化，建立折曲表面輪廓發生之充要條件，並繪製成無因次化切深之函數。此折曲表面圖將複雜的折曲表面充要條件簡化表現出來，提供製造者快速判認各種切深條件與刀具幾何下之表面幾何形貌，此外，透過此折曲表面圖將可在無折曲表面發生前提下快速選擇最大軸向切深與最大體積移除率之切深條件或相對應之刀具。
本文最後以折曲表面輪廓為基礎，為連續銑削建立一通用表面誤差與切削力模式，探討連續順逆銑對產品尺寸誤差及表面粗糙度之影響，提出一先逆銑後順銑之連續銑削。為瞭解決逆銑時發生之過切現象，本論文能提出一徑向切深分配加工策略，實驗結果證實此一加工策略能在兩道次加工後在不犧牲表面粗糙度前提下降低誤差至10 mm軸向切深中最大誤差約10 μm.

Without a systematic knowledge of the various sources of errors and the roles of various process parameters, machine operators and process designers often have difficulties finding optimal machining conditions to obtain parts of high dimension and form accuracy in the machining process. This thesis presents a systematic analysis on the part error composition for an EDM and peripheral milling process and offers machining strategy to facilitate the process planning process in meeting the part tolerance requirement.
In general, the form error of the machined part in a machining system can be attributed to several factors, including tool wear, thermal deformation, the machine tool positioning error and process-induced process error. Although the latter two factors are often more significant, their effects on the machined parts accuracy are more elusive and difficult to predict due to their inherent statistical dispersion property. It is therefore the subject of this thesis to quantitatively relate the parts error to the machine tool errors and process-induced errors in machining systems. The form error models are constructed in the presence of volumetric error of different type 3-axis machine tools and errors of milling and the EDM processes. The variance analysis of the error terms is performed on basis of the probability convolution method and the covariance analysis. The strategy of the individual machine system is then proposed on basis of the error analysis results.
An understanding of the mechanism of surface generation and the influence of machining conditions on the profile and magnitude of the machined surface form error would be helpful in facilitating the process planning process. For peripheral milling system, an analytical method for predicting the existence and positions of kinks on the machined surface are presented. The surface and kink generation mechanism is revealed through examining the cascading milling force convolution process, leading to the establishment of kink criteria and the construction of a kink chart with normalized radial, axial cutting depths, number of flutes and radial cutting constant as key parameters for a general peripheral milling process. An algebraic closed-form expression for kink position for a given tool geometry has been derived. For successive milling the wavy surface with kinks, a generalized force and form error model with dual shearing and ploughing mechanisms are further developed. The effect of the combination of up and down milling configuration on the form error was discussed.
Error models proposed in this thesis are validated by a series of machining experiments. The proposed kink criteria or the associated kink chart can be conveniently used to determine whether the cutting conditions will result in a kinked machined surface in peripheral milling. Basic profiles of the kinked surface with respect to the normalized cutting depths in both up and down milling are presented. Furthermore, strategies for generating a kink free surface with maximum axial cutting depth and material removal rate are proposed. It is shown that the suitable cutting depths condition and machined surface profile for any tool diameter and tooth number can be quickly determined by referring to the kink chart proposed in this thesis. In successive milling, a proper milling configuration with low surface roughness and high accuracy form is established.

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