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<!DOCTYPE html>
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<title>動力計實驗SOP | HiAPI-C# 2025 </title>
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<h1 id="動力計實驗sop">動力計實驗SOP</h1>
<p>以動力計擷取三方向力量，並計算銑削力係數。</p>
<h2 id="動力計設置拍照">動力計設置拍照</h2>
<p>架好實驗設備後，分別用手推XYZ三方向，同時觀察動力計輸出是否正確。</p>
<p>此過程需拍照或攝影，畫面中要同時有動力計輸出及手推。</p>
<p>確保動力計的接線正確、正負號正確，方便追朔實驗現場。</p>
<h2 id="刀具">刀具</h2>
<p>刀具需採用無圓角端銑刀。刀具參數建議：</p>
<ul>
<li>D10</li>
<li>Flute4</li>
<li>Helix35</li>
</ul>
<p>刀具的刃數、螺旋角、前角無特別限制，但須與刀具廠牌型號一併詳實紀錄。</p>
<p>刀具直徑採用10mm是為了怕材料太難切導致斷刀。10mm是以inconel718在此實驗為安全標準設立。</p>
<h2 id="工件路徑">工件/路徑</h2>
<p>工件尺寸： 動力計長寬 x 方便夾持高度(50mm)</p>
<p><img src="img/fixWorkpiece.jpg" alt="fix-workpiece.jpg"></p>
<p><img src="img/StraightLineTraining-path.png" alt="training-path"></p>
<p>切深為0.5mm。</p>
<p>路徑分類以關鍵字表示：low、high、through。</p>
<p>low為低轉速、high為高轉速、through為穿越道。
共切8刀，分別為low1、low2、low3、high1、high2、high3、through1、through2。</p>
<p>如果材料有限，使用low2、low3即可完成訓練。</p>
<p>low1故意切在邊緣，是為使through1可以平穩進入切削區域。</p>
<p>high系列的每刃進給與low系列一致，但轉速不同，主要觀察轉速是否會造成力量差異。
如果受限於材料或機台等其他原因，可以優先捨棄high2、high3。</p>
<p>through1、through2的CWE持變，作為驗證使用。</p>
<p>如果材料過硬，可以降低切深進行實驗。</p>
<h2 id="實驗結果">實驗結果</h2>
<p>動力計數據需保留。</p>
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<h1 id="第一離隙角避讓">第一離隙角避讓</h1>
<p>本文所述離隙角皆為第一離隙角，即離切削區域最近的離隙角(Relief Angle)。或稱清角(Clearance Angle)。</p>
<p>銑刀刀刃在切削過程中為擺線運動，為下圖紅色擺線。藍色圓為刀具包絡圓。</p>
<p>紅色擺線之內(即朝刀具包絡圓圓心方向)為已切削區域；紅色擺線之外為未切削區域，如果離隙面在該處則會與未切削材料產生碰撞。
所以<strong>標示RA(Relief Angle的縮寫)處為最小所需離隙角。</strong></p>
<p><img src="relief-angle.png" alt="relief-angle.png"></p>
<p>如果實際刀具離隙角小於最小離隙角，則清角面會壓到未切削工件，造成刀具及工件受力增加，使得刀具振動加大且工件表面回彈，表粗驟升，會降低刀具壽命。</p>
<h2 id="最小所需離隙角計算">最小所需離隙角計算</h2>
<p>於定軸加工，最小所需離隙角可由進給、轉速、刀具半徑算出；於多軸同動加工，需由程式對每個接觸點批量計算。</p>
<p>以下簡述定軸加工的最小所需離隙角計算方式。</p>
<p><span class="math">\(\vec r_p = \left(t\cdot v-R\cdot\sin\left(t\cdot w\right),R-R\cdot\cos\left(t\cdot w\right)\right)\)</span></p>
<p><span class="math">\(\vec r_b = \left(a\cdot v-R\cdot\cos\left(s\right),R-R\cdot\sin\left(s\right)\right)\)</span></p>
<p>其中
<span class="math">\(\vec r_p\)</span> 為紅色擺線位置向量；
<span class="math">\(\vec r_b\)</span> 為藍色圓位置向量；
<span class="math">\(R\)</span> 為刀具半徑(mm)；
<span class="math">\(w\)</span> 為轉速(rad/s)；
<span class="math">\(v\)</span> 為進給(mm/s)；
<span class="math">\(t\)</span> 為時間；
<span class="math">\(s = t\cdot w\)</span> ；
<span class="math">\(a\)</span> 為指定時間，作為常數使用。</p>
<p>令速度向量為</p>
<div class="math">
\[
\vec v_p = \frac{d\vec r_p}{dt} ,
\vec v_b = \frac{d\vec r_b}{ds}
\]</div>
<p><span class="math">\(\vec v_p\)</span> 、 <span class="math">\(\vec v_b\)</span> 兩向量夾角為最小所需離隙角。</p>
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<h1 id="刀具壽命與磨耗">刀具壽命與磨耗</h1>
<p>刀刃損傷模式繁多，可歸因於瞬間失效的模式，含斷刀、熱崩刃，見<a href="../availability/index.html">本文</a>；而歸因於長時間消耗而失效的模式，<u>建議以<strong>刀面磨耗</strong>作為評估刀具壽命的標的</u>。</p>
<p>HiNC採用磨耗模式<a id="fnref:1" href="#fn:1" class="footnote-ref"><sup>1</sup></a>：</p>
<p><span class="math">\(W(T) = \frac{k(T) L P}{H(T)}\)</span></p>
<p>其中W為磨耗量、k為磨耗係數、L為接觸長度、P為壓力、H為硬度、T為溫度。</p>
<p>HiNC計算的磨耗包含：</p>
<ul>
<li>刀面磨耗(Crater Wear)</li>
<li>刀緣磨耗寬度(Flank Wear Width)</li>
<li>刀緣磨耗深度(Flank Wear Depth)</li>
</ul>
<p>此處刀面磨耗係指刀面磨耗深度。</p>
<p>刀緣磨耗寬度在論文中最常用來作為評估標的，因它有量測標準。刀具在平面運動中，會先磨刀峰再磨刀緣，所以在實驗室可以刀緣磨耗寬度評估總磨耗。</p>
<p>但若銑削中刀具有上下運動，刀緣會在刀峰磨完前發生隨機碰撞，此時刀緣磨耗寬度就不具評估總磨耗的價值。</p>
<p>HiNC 計算的 刀緣磨耗寬度，假設刀緣沒有隨機碰撞，僅適用於平面切削，HiNC保留這項數值於研究用途。</p>
<div class="footnotes">
<hr>
<ol>
<li id="fn:1">
<p>Lee, R. S, and J. L Jou. &ldquo;Application of Numerical Simulation for Wear Analysis of Warm Forging Die.&rdquo; Journal of Materials Processing Technology, Proceedings of the 6th Asia Pacific Conference on materials Processing, 140, no. 1 (September 22, 2003): 43–48.<a href="#fnref:1" class="footnote-back-ref">&#8617;</a></p>
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