| Summary: | 碩士 === 國立成功大學 === 機械工程學系碩博士班 === 101 === Milling can achieve complex geometry and high surface quality part. Therefore, milling is widely utilized in precision manufacturing industry. However, milling induces residual stress and deformation, resulting in poor quality parts, such as the flatness of plate. In this article, systematic method of experiment design is used to analyze the influence of flatness on plate and to establish a model of flatness in milling. The model is used to find maximum material removal rate under the constraint of flatness. First, we utilize the cutting coefficients and convolution milling force model to find the milling parameters under the limit of vacuum chuck and spindle. Then, we use response surface methodology and combination of orthogonal array (L9) and Box-Behnken design in order to analyze milling parameter of flatness and obtain an accurate model of flatness with efficient number of experiments. Also, the flatness model considers process variation due to the fact that it is more efficient for industry. The result of experiment showed that high speed, low feed per tooth and low depth of cut constitute the key parameters for better flatness. Finally, we use the derived flatness model incorporating process variation effect to find the optimal process parameters to achieve the maximum material removal rate under the constraint of flatness.
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