本研究使用方螺紋型導電高分子ESD 410C作為工具電極及多軸運動式電解複合拋光機，對盲孔直徑8、6、4 mm之SKD61熱作模具鋼之內孔表面進行電解複合磨粒拋光，探討氧化鋁磨粒粒徑(3, 1, 0.3 μm)、加工負荷(0.3 ~ 0.5 N)、加工電流(0 ~ 400 mA)以及加工時間(0 ~ 8 min)等實驗參數，對工件內孔表面粗糙度Rmax 、Ra之影響。
純磨粒實驗(不通電)可得知，使用含磨粒粒徑1 μm的電解液，在負荷0.4 N下，加工時間8分鐘時之工件表面粗糙度由Rmax = 0.5 μm、Ra = 0.12 μm降至Rmax = 0.22 μm、Ra = 0.054 μm；
在負荷0.4 N、加工電流200 mA下，加工時間8分鐘時之工件表面粗糙度Rmax = 0.29 μm、Ra = 0.069 μm。
在工具電極無進給且採用兩階段的電解複合磨粒拋光實驗得知，第一階段係使用含磨粒粒徑1 μm的電解液，以加工電流200 mA與負荷0.4 N，加工時間4分鐘後，工件之表面粗糙度Rmax = 0.26 μm、Ra =0.052 μm。在第二階段使用粒徑0.3 μm之磨粒，以加工電流200 mA與負荷0.4 N，再加工到4分鐘。經二階段加工後，工件之表面粗糙度達到Rmax = 0.12 μm、Ra =0.021 μm，工件內孔表面已達光亮鏡面。
最後，在工具電極進給電解複合磨粒拋光實驗中，含磨粒粒徑1 μm的電解液中以及加工電流200 mA與負荷0.4 N下，對內孔直徑分別為8、6、4 mm進行加工，於加工時間24分鐘後之工件表面粗糙度達到為Rmax = 0.017 ~ 0.018 μm、Ra = 0.036 ~ 0.038 μm，工件內孔表面均已達光亮鏡面。



關鍵字：導電高分子、盲孔、模具鋼、電解複合磨粒拋光、鏡面

In this study, a square thread shape of conductive polymer (ESD 410C) was employed as a tool electrode to compositely electrolyze and abrasive polish the inner surface of bilnd hole workpiece whose diameter is 8, 6, 4 mm made of SKD61 hot work die steel using a polishing machine with multi-axis motions. The effects alumina abrasive particle size (3, 1, and 0.3 μm), load (0.3 ~ 0.5 N), current (0 ~ 400 mA), and polishing time (0 ~ 8 min) on the inner surface roughness of workpiece were investigated.
In the abrasive polishing under a load of 0.4 N with a grit size of 1 μm in the electrolyte, the surface roughness Rmax and Ra decreased from 0.5 μm and 0.12 μm to 0.22 μm and 0.054 μm after 8 minutes, respectively.
In the electrolytic polishing under a current of 200 mA and a load of 0.4 N, the surface roughness Rmax and Ra decreased to 0.29 μm and 0.069 μm after 8 minutes, respectively.
The two-stage electrolytic abrasive polishing without feeding was conducted. In the first stage, the surface roughness Rmax and Ra decreased quickly to 0.26 μm and 0.052 μm, respectively under the load of 0.4 N, with the grit size of 1 μm and a current of 200 mA in electrolyte within 4 minutes of polishing time. In the second stage, Rmax and Ra decreased to 0.12 μm and 0.021 μm, respectively using the abrasive particle size of 0.3 μm for 4 minutes. The inner surface of the workpiece has achieved a bright mirror.
Finally, a electrolytic abrasive polishing process with feeding was conducted to the bilnd hole whose diameter is 8, 6, 4 mm.The surface roughness Rmax and Ra decreased quickly to 0.17 ~ 0.18 μm and 0.036 ~ 0.038 μm under a load of 0.4 N, with a grit size of 1 μm and a current of 200 mA in the electrolyte after 24 minutes. The inner surface of the workpiece has also achieved a bright mirror.

Keywords: Conductive polymer, Blind hole, Die steel, Electrolytic abrasive polishing, Mirror

論文審定書 i
誌謝 ii
摘要 iii
Abstract iv
目錄 v
圖次 viii
表次 xii
第一章 緒論 1
1.1 研究背景 1
1.2 文獻回顧 4
1.2.1 電化學加工演變 4
1.2.2 電解複合磨粒拋光法 10
1.2.3 電解液對腐蝕之影響 18
1.2.4 導電高分子材料 19
1.3 研究目的 21
第二章 實驗設備與實驗方法 22
2.1 電解複合磨粒內孔拋光加工實驗設備及實驗方法 22
2.1.1 多軸運動式電解複合磨粒拋光機系統 22
2.1.2 工件迴轉與施力模組 24
2.1.3 工具電極旋轉與往復運動模組 24
2.1.4 工具電極進給模組 25
2.1.5 電壓電流供應系統 25
2.1.6 電解液循環系統 25
2.2 實驗資料蒐集分析與訊號量測設備 27
2.3 實驗材料之特性與幾何形狀 28
2.3.1 工件材料與幾何形狀 28
2.3.2 工具電極 29
2.3.3 工具電極幾何形狀選擇 30
2.3.4 電解液的選擇 31
2.4 實驗材料之前處理方式 33
2.4.1 SKD61工件實驗前處理 33
2.4.2 工具電極前處理 34
2.5 實驗條件設定 35
2.6 實驗步驟 37
2.6.1 實驗流程 37
2.6.2 工件內孔面量測 39
第三章 實驗結果與討論 40
3.1 純磨粒作用 41
3.1.1 轉速 42
3.1.2 加工時間效應 42
3.1.3 磨粒與負荷 45
3.1.4 純磨粒加工機制 54
3.2 純電解作用 57
3.2.1 電壓電流曲線 57
3.2.2 工件材料解離現象之觀察 59
3.2.3 加工電流的效應 61
3.2.4 加工電流對工件表面粗糙度的影響 66
3.2.5 純電解加工機制 67
3.3 電解複合磨粒作用 68
3.3.1 電解複合磨粒加工與鈍態膜之關係 68
3.3.2 電解複合磨粒加工現象之觀察 69
3.3.3 電解複合磨粒加工 71
3.3.4 電解複合磨粒拋光的加工機制 75
3.3.5 二階段電解複合磨粒拋光 76
3.4 全表面拋光 82
3.4.1 電解複合磨粒進給拋光 82
3.4.2 工件全表面拋光成果圖 91
第四章 結果與未來研究方向 92
4.1 結論 92
4.2 未來研究方向 93
參考文獻 94

[1] 蔡芯穎, “使用導電高分子工具於電解複合研磨的鋼之表面特性研究”, 國立中山大學機械與機電工程學系碩士論文, (2011).
[2] 李承佑, “電解擦光加工參數304不銹鋼表面粗糙度之影響”, 國立中山大學機械與機電工程學系碩士論文, (2012).
[3] J.A. McGeough, “Principles of electrochemical machining. ”, Chapman and Hall , (1974) p. 1-10.
[4] 魏展鴻, “使用導電高分子工具對不鏽鋼表面的電解擦光之研究”, 國立中山大學機械與機電工程學系碩士論文, (2013).
[5] 杜致緯, “使用導電高分子工具電解複合磨粒拋光圓桿件之研究”, 國立中山大學機械與機電工程學系碩士論文, (2014).
[6] 林逸城, “多軸運動式電解複合磨粒拋光機之研製以及不鏽鋼內孔拋光之研究”,國立中山大學機械與機電工程研究所碩士論文, (2015).
[7] 李智弘, “使用導電高分子工具電解複合磨粒拋光模具鋼內孔面之研究”,國立中山大學機械與機電工程研究所碩士論文, (2016).
[8] K. P. Rajurkar, J. Kozaka, B. Wei and J.A. McGeough, “Study of pulse electrochemical machining characteristics”, CIRP Annals-Manufacturing, Vol.5(1993), p. 231-234.
[9] C. L. Faust, “Electro-polishing I: The practical side”, Metal Finishing, (1982) p. 21-25.
[10] C. L. Faust, “Electro-polishing II: The practical side”, Metal Finishing, (1982) p. 59-63.
[11] T. S. Hahn and A.R. Marder, “Effect of Electropolishing Variables on the Current Density-Voltage Relationship”, Metallography, vol.21 (1988), p. 365-375.
[12] 佐治孝, “電解研摩と化学研摩の機構”, 金屬表面技術, Vol.14 (1963) No.4 , p. 129-134.
[13] S. C. Tam, “Electrochemical polishing of biomedical titanium orifice rings”, Journal of Materials Processing Technology, vol. 35 (1992) p.83-91.
[14] 釜田浩, “電解バフ複合加工の特性解析と性能向上に関する研”, 大阪工業大学博士論文, (1993), p. 29-53.
[15] S. Murali, M. Ramachandra, K. Murthy, and K. Raman, “Development of electropolishing tecniques on metals and alloys”, Praktische Metallographie, vol.33 (1996) No. 7, p. 359-68.
[16] K. Seimiya, “Electroabrasive Mirror Finishing of the Inner Surfaces of Stainless Steel Pipes of Small Diameter”, Shinku, Vol. 40 (1997) No. 6, p.523-528
[17] H. Hocheng and P.S. Pa, “Electropolishing and electrobrightening of holes using different feeding electrodes. Journal of Materials Processing Technology”, Vol. 90 (1999), p. 440-446.
[18] L. S. Andrade, S.C. Xavier, R.C. Rocha-Filho, N. Bocchi and S.R. Biaggio,“Electropolishing of AISI-304 stainless steel using an oxidizing solution originally used for electrochemical coloration”, Electrochimica Acta, vol. 50 (2005) 2623-2627.
[19] P. S. Pa, “Design of thread surface finish using ultrasonic-aid in electrochemical leveling”, The International Journal of Advanced Manufacturing Technology, vol.36 (2008), p. 1113-1123.
[20] S. J. Lee, Y.M. Lee and M.F. Du, “The polishing mechanism of electrochemical mechanical polishing technology”, Journal of Materials Processing Technology, Vol.140 (2003) (1-3) p. 280-286.
[21] Tsukasa Harada, Koichi Seimiya, “Electro-abrasive Polishing and its Application to the Manufacturing Process”, Journal of The Surface Finishing Society of Japan, Vol. 61 (2010) No. 4, p. 309.
[22] S. Okawa, A. Hossain, M. Kanatani, K. Watanabe, O. Miyakawa, “Surface properties of electrochemically buffed titanium casting”, Dental Materials Journal, vol.23 (2004) No.4 , pp. 504-511.
[23] 前畑英彦, 釜田浩 和 山本昌彦, “電解複合鏡面加工の研究”, 精密機械, Vol. 51 (1985) No. 7, p. 1420-1427.
[24] 清宮紘一, “電解砥粒研磨による鋼材の精密鏡面仕上げ”, 鉄と鋼, Vol. 72 (1986) No. 8, p. 904-908.
[25] 木本康雄, 垣野義昭 和 中川眞二, “高精度電解複合鏡面加工の研究”, 精密工学会誌, Vol.54 (1988) No.2, p. 353-358.
[26] 釜田浩, 木本保夫, 中川雅之 和 垣野義昭, “電解複合砥粒加工作用に関する研究 (第2報) ”, 電気加工学会誌, Vol. 23 (1989-1990) No. 45, p. 1-12
[27] 木本保夫, 釜田浩, 諸岡寿史, 中川雅之, 垣野義昭 和 山本昌彦, “円筒外面の高精度電解複合鏡面加工の研究”, 精密工学会誌, Vol. 56 (1990) No. 11, p. 2099-2104.
[28] 馬場吉康 和 佐藤憲二, “電解複合研磨による金属の超鏡面化技術”, 表面科学, Vol.11 (1990) No.6, p. 368-374.
[29] 釜田浩, “電解バフ複合加工の特性解析と性能向上に関する研”, 大阪工業大学博士論文, (1993), p. 159-171.
[30] A. Iwabuchi, T. Tsukamoto, Y. Tatsuyanagi, N. Kawahara and T. Nonaka, “Electrochemical approach to die steel in Na2S04 solution”, Wear, Vol.156 (1992) , p. 301-313.
[31] J. R. Galvele, S. Begum, “Corrosion, Pitting”, Reference Module in Materials Science and Materials Engineering, (2016).
[32] P. Marcus, V. Maurice, H.-H. Strehblow “Localized corrosion (pitting): A model of passivity breakdown including the role of the oxide layer nanostructure”, Corrosion Science, Vol.50 (2008), p. 2698-2704.
[33] H. Shirakawa, E.J. Louis, A.G. Macdiarmid, C.K. Chiang, A. J. Heeger, “Synthesis of electrically conducting polymers: Halogen derivatives of poly-acetylene, (CH)X”, Journal of The Chemical Society, Chemical Communications, Vol.16 (1977), p. 578-580.
[34] A. C. Wang and S. H. Weng, “Developing the polymer abrasive gels in AFM process”, Journal of Materials Processing Technology, Vol.192 (2007), p. 486-490.