Abstract
摘要:本計畫針對新興科技所需微小化產品之精微加工技術,提出系統性的研究分析,並
藉此開發可供產業界應用的振動輔助精微加工之最佳條件。電子產品的微小化是近
年來發展的趨勢,過去與未來的走向均十分明確。然而工具機並未隨產品尺寸縮小
而微型化,此與近年來世界上節能減碳的目標背道而馳。因此發展微型工具機在微
小元件加工上是不可抵擋的趨勢。在微型工具機上進行的精微加工技術,必須保證
其加工精度可達需求。因此有必要開發在微型工具機上進行的前瞻精密加工技術。
本計畫之主軸為配合產品微小化特性,發展振動輔助銑削應用於微型工具機技術。
同時引進微量潤滑的概念,期能與國際間在前瞻切削領域接軌。也期望藉由此新研
究對精密加工及綠色製造有所貢獻。目前振動輔助切削技術主要使用於傳統工具機
上,已經證實可以有效降低切削力、提升加工面品質與延長刀具壽命。然而過去的
振動輔助切削研究,其實驗條件僅針對單一振動頻率與振幅,對於振動輔助切削技
術之機制並不甚了解。目前所知為導入振動輔助加工技術,的確對切削加工有助
益。但是否有任何加工條件的限制則一無所知。因此將此一技術應用於精微加工上
仍有其困難。本研究除將振動輔助加工技術導入微銑削之外,擬針對振動條件及切
削條件進行交叉分析。期能找出振動輔助微銑削之最佳加工條件,以供未來工業界
在此前瞻製程技術的開發之參考。除此之外,在微型工具機上採用微量潤滑相關研
究在國外仍在起步階段,文獻的報導更是乏善可陳,探討微量潤滑在振動輔助微銑
削之效益正是本計畫的另一個研究主軸。
本計畫將以前瞻的振動輔助切削加工技術開發為主軸,同時著手為複合式加工技術進
行完整的探討。本項加工技術成熟之後,不但可用於精密元件製造之外,更可應用於
精微模具的設計與製造。本計畫將以微銑削為加工方式,研究振動輔助切削與微量潤
滑技術在微型工具機的適用性,而逐步建立此加工方法應用於微型工具機之加工資料
庫,並同步提升國內在機械式微加工的研究能量與技術。
Abstract: The objective of this research is to experimentally investigate the machining
performance of vibration assisted milling on a miniature machine tool. Vibration-assisted
machining combines precision machining with small-amplitude tool or workpiece vibration to
improve the fabrication process. This study will develop the relationship between the
vibration parameters (i.e. frequencies and amplitudes) and the machining performance of
micro-milling. The application of minimum quantity lubrication in vibration-assisted
micro-milling will be also studied. With the study on machining performance as a starting
point, the results from this project can support further research on issues of tool breakage,
work integrity, and dimensional accuracy.
The vibration-assisted cutting has been applied to a number of processes from turning to
drilling to grinding and proved to be an effective method of achieving improved surface
finishes, better form accuracy, and low cutting forces compared to conventional machining.
The periodic separation between the tool rake face and chip is related to observed reductions
in machining forces and chip thickness, which are related to improvements in surface finish
and extended tool life. However, most previous research focuses on machining under certain
input frequency and amplitude. The results are limited to the comparison of machining
performance between traditional cutting and vibration-assisted machining. The optimal
machining parameters are not entirely studied. The application of vibration-assisted cutting is
not fully understood due to the lack of parametric studies, not mention to its application in
micro machine tools. As the miniaturization of electronic devices has become a trend, the
development of micromachining on miniature machine tools is inevitable. It has gained
increasing importance in the manufacture of optical, mechanical, biomedical, and electronic
components, and even to create dies and molds for further mass production.
In this research, experimental observations are conducted to investigate the vibration
parameters on surface finish of machined hardened steels and tool wear progressions in
micro-milling. The mechanism of vibration-assisted milling will be also discussed for
choosing the optimal machining parameters in the future. The goal of this study is a
compilation of specific database for the rigorous process planning on vibration-assisted
micro-milling. It will also provide a solid foundation for further research efforts in the
development of mathematical model for micromachining, the control of part integrity, and
the optimization of miniature machine utilization.
Keyword(s)
振動輔助切削
微銑削
微量潤滑
Vibration assisted cutting
micro-milling
MQL