微銑削主軸轉速與表面粗糙度關聯性之研究

Abstract

微元件在市場上的需求在近年來不斷增加，大量應用在航太、生醫、電子、通訊及汽車產業。而微銑削是生產微元件的一種製造方式，可以製造尺寸由幾十微米至厘米的微元件。 本論文使用直徑0.5mm、0.3mm兩種市售的微端銑刀和一般直徑10mm的端銑刀，加工6061鋁合金和S20C低碳鋼兩種金屬材料，以不同的切削速度加工後，利用光學輪廓儀量測表面粗糙度，經比較和觀察後發現直徑0.5mm及0.3mm的銑刀加工後之材料，表面粗糙度並未隨著主軸轉速的提升而顯著降低，而且發現切屑容易形成破片及粉末狀，並黏附在加工後的表面和刀具上，這些現象是一般傳統尺寸銑削不易發生的，針對這個問題本論文提出使用高壓空氣將切削液送入切削處的方法，可以改善加工後的表面粗糙度和刀具磨耗。

Miniaturized components are increasing in demand for various application, such as aerospace, biomedical, electronics, communications and automotive. Micro-milling is a method to fabricate miniature devices and components with features that range from tens of micrometers to a few millimeters in size. This study presents an experimental investigation of the different tool diameter with 0.3mm, 0.5mm and 10mm of 6061 aluminum alloy and S20C steel in traditional milling and micro milling process. It is found that cutting under higher spindle speed results in worse surface roughness due to chip adhesion. The chip always turns into arc chip and powdery in the micro milling process. But these phenomena are not easy to occur in the traditional milling process. This paper proposes a method which send the cutting fluid to the cutting zone by using compressed air may improve the surface roughness and adhesive wear of the tool.