本研究成功開發用於檢測放電加工液中鐵顆粒濃度及黏度之整合裝置。此整
合裝置包含流體抽取單元、鐵顆粒濃度量測單元、黏度量測單元及顯示單元。鐵
顆粒濃度量測單元使用鐵相分析技術，鐵顆粒被吸附於磁極間隙而改變磁通量，
藉由霍爾元件感測器輸出訊號得到鐵顆粒濃度。黏度量測單元使用活塞擠壓油壓
缸內的放電加工液，並利用負荷計量測活塞的擠壓負荷，藉由量測負荷計輸出訊
號得到放電加工液黏度。
鐵顆粒濃度量測單元係使用自製之鐵顆粒濃度液校正，經過數次測試得知，
鐵顆粒量測單元之量測誤差小於2.3 ppm。黏度量測單元係使用一般用途標準黏度
液進行校正，經過數次測試得知，黏度量測單元之量測誤差可達5%以下。應用此
整合裝置檢測放電加工液中鐵顆粒濃度及黏度，並探討鐵顆粒濃度對材料移除率
及加工後工件表面粗糙度的影響。由實驗結果得知，本檢測裝置可用於檢測放電
加工液中鐵顆粒濃度，另一方面，放電加工液中鐵顆粒濃度對材料移除率及加工
後工件表面粗糙度有顯著影響，當鐵顆粒濃度超過270 ppm 時更換放電加工液可
維持較佳的加工表現，這說明了一般放電加工機加裝放電加工液中鐵顆粒濃度檢
測裝置之重要性。

The integrated apparatus for detecting ferrous debris concentration and viscosity in
EDM fluid has been developed successfully. This apparatus contains a sampling unit,
and measurement units of the ferrous debris concentration and viscosity with a displayer
unit. Measurement unit of the ferrous debris concentration adopts Ferrography
technology, where ferrous debris are captured at the gap between the poles of magnet to
change the magnetic flux, and its concentration is measured by using the output signal
of Hall effect sensor. Measurement unit of the viscosity uses a piston to squeeze the
EDM fluid in a hydraulic cylinder, and a load cell is used to measure the squeeze load.
The output signal of load cell is transformed into the viscosity of EDM fluid.
The ferrous debris concentration is calibrated using the given concentrations, and
the maximum error is less than 2.3 ppm under numerous tests. The viscosity is
calibrated using the general purpose viscosity fluids, and the maximum error is less than
5% under numerous tests. The ferrous debris concentration and viscosity in EDM fluid
are detected using this integrated apparatus, and the effect of ferrous debris
concentration on material removal rate and surface roughness of the machined
workpieces is investigated. Experimental results show that this apparatus is capable of
detecting ferrous debris concentration in EDM fluid. On the other hands, ferrous debris
concentration in EDM fluid has an appreciable impact on the material removal rate and
surface roughness of the machined workpieces. To maintain the performance of EDM
machine, it is necessary to change the EDM fluid when the ferrous debris concentration
is larger than 270 ppm. This indicates that the general EDM machine equips with a
detecting apparatus for ferrous debris concentration in EDM fluid is important.

論文審定書 ....................................................................................................................... i
誌謝 .................................................................................................................................. ii
摘要 ................................................................................................................................. iii
Abstract ............................................................................................................................ iv
目錄 .................................................................................................................................. v
圖次 ................................................................................................................................ vii
表次 ................................................................................................................................. ix
第一章 緒論 .................................................................................................................... 1
1.1 研究背景 ........................................................................................................... 1
1.2 文獻回顧 ........................................................................................................... 2
1.3 放電加工液中鐵顆粒濃度檢測技術 ............................................................... 9
1.4 研究目的 ......................................................................................................... 10
第二章 檢測裝置之設計與製作 ................................................................................... 11
2.1 流體抽取單元 .................................................................................................. 11
2.2 鐵顆粒濃度量測單元 ..................................................................................... 12
2.2.1 霍爾感測元件 ...................................................................................... 12
2.2.2 鐵顆粒量測方法 .................................................................................. 12
2.2.3 磁鐵設計 .............................................................................................. 15
2.2.4 鐵顆粒量測單元製作 .......................................................................... 16
2.3 黏度量測單元 ................................................................................................. 20
2.3.1 黏度量測原理 ...................................................................................... 20
2.3.2 黏度量測單元製作 .............................................................................. 23
2.3.3 行程控制與保護電路 .......................................................................... 24
2.4 顯示單元 ......................................................................................................... 25
2.4.1 訊號轉換流程 ...................................................................................... 25
2.4.2 顯示單元電路 ...................................................................................... 27
2.5 檢測裝置操作流程 ......................................................................................... 35
2.6 量測元件校正與量測範圍 ............................................................................. 38
2.6.1 鐵顆粒濃度量測元件 .......................................................................... 38
2.6.2 黏度量測元件 ...................................................................................... 38
2.6.3 量測範圍與校正參數 .......................................................................... 39
第三章 黏度與鐵顆粒濃度檢測結果與討論 .............................................................. 41
3.1 黏度 ................................................................................................................. 41
3.1.1 黏度量測理論值 .................................................................................. 41
3.1.2 黏度量測訊號波形 .............................................................................. 41
3.1.3 黏度量測結果討論 .............................................................................. 44
3.2 鐵顆粒濃度 ..................................................................................................... 46
3.2.1 量測訊號波形 ...................................................................................... 46
3.2.2 重現性測試與校正曲線 ...................................................................... 47
3.3 顯示單元運算 ................................................................................................. 48
第四章 放電加工液之檢測標準 .................................................................................. 49
4.1 實驗設備 ......................................................................................................... 49
4.2 實驗材料 ......................................................................................................... 51
4.3 實驗材料前處理 ............................................................................................. 53
4.4 實驗條件設定 ................................................................................................. 53
4.5 實驗流程 ......................................................................................................... 55
4.6 非線上檢測的結果 .......................................................................................... 56
4.6 線上檢測的結果 .............................................................................................. 62
第五章 結論與未來展望 .............................................................................................. 66
5.1 結論 ................................................................................................................. 66
5.2 未來展望 ......................................................................................................... 67
參考文獻 ........................................................................................................................ 68

1. 倉藤尚雄、鳳誠三郎原著，鄒大鈞譯，「放電加工」，復漢出版社
2. S.B.M, “About the role of debris on the gap during electrical discharge machining”,
Annals of the CIRP,vol.39,pp.197-199,1990
3. 陳以諾,「檢測潤滑油的鐵顆粒濃度及黏度之整合裝置」,國立中山大學機械與
機電工程學系碩士論文 (2009)
4. 邱源成編著, “磨潤學”, 國立中山大學機械與機電工程學系, 2012, 370-379
5. B. J. Roylance, “Ferrography-then and now”, Tribology International, 38 (2005)
857-862
6. W. W. Seifert and V. C. Westcott, “A method for the study of wear particles in
lubricating oil”, Wear, 21(1972)27-42.
7. D. Scott and V. C. Westcott, “Predictive maintenance by ferrography”, Wear,
44(1977)173-182.
8. D. Scott, P.J. McCullagh and G.W. Campbell,“Condition monitoring of gas turbines -
An exploratory investigation of Ferrographic trend analysis”, Wear, 49(1978)373-389
9. A. L. Price and B. J. Roylance, “Rotary particle depositor”, Industrial Lubrication
and Tribology, 37(1985)747-767.
10. Y. C. Chiou, “Study of wear particle deposition by an improved rotary ferrographic
analyzer”, Wear, 146(1991)137-147.
11. Y. C. Chiou, R. T. Lee, Y. A. Chang and W. F. Kuo, “Fundamental characteristics
of wear particle deposition by an improved rotary ferrographic analyser”, Wear,
155(1992)285-295.
12. O. Lloyd and A. F. Cox, “Monitoring debris in turbine generator oil”, Wear,
71(1987)79-91.
13. P. W. Centers, “Laboratory evaluation of the on-line ferrograph ”, Wear,
90(1983)1-9.
14. K. W. Chambers, M. C. Arneson and C. A. Waggoner, “An on-line ferromagnetic
wear debris sensor for machinery condition monitoring and failure detection”,
Wear, 128(1988)325-337.
15. Y. Liu, Y. B. Xie, C. J. Yuan and Z. Y. Li, “Research on an on-line ferrograph”,
Wear, 153(1992)323-330.
16. N.K.Myshkin, L.V. Markova, M.S. Semenyuk, H. Kong, H.-G. Hanand E.-S. Yoon,
“Wear monitoring based on theanalysis of lubricant contamination by optical
ferroanalyzer”, Wear, 255(2003)1270-1275.
17. W. F. Kuo, Y. C. Chiou and R. T. Lee, “Fundamental characteristics of wear
particle deposition measurement by an improved on-line ferrographic
analyzer” ,Wear, 208(1997)42-49.
18. Y. C. Chiou, R. T. Lee and C. Y. Tsai, “An on-line Hall-effect device for
monitoring wear particle in oils”, Wear, 223(1998)44-49.
19. C. Frei, “Process and apparatus for controlling the concentration of solid
particles in suspension in a liquid fluid” ,U.S. Patent, (1982) NO.4362989.
20. El-Menshawy et al., “Methods and apparatus for monitoring the condition of
dielectric liquid in electric discharge maching” ,U.S. Patent, (1983) NO.4392110
67
21. 盧明智,盧鵬任，「感測器應用與線路分析」，全華圖書股份有限公司
22. R. T. Lewis, “Method and device including a bed of ferromagnetic fibers and
magnetic flux sensor for measuring the amount of magnetic particles on a liquid”,
U.S. Patent,(1987)No.4692698
23. T. Kayaba, K. Kato and T. Akagaki, “Ferrographic study of wear (first report) the
fundamental characteristics of magnetic wear debris separation analysis”, J. JSLE,
29(1984) 745-752.
24. W. F. Kuo, Y. C. Chiou and R.T. Lee, “The Analysis of Magnetic Field and the
Behavior Studies of Wear Debris Deposition for the Stationary Ferrographic
Analyzer”, Journal of the Chinese Society of Mechanical Engineers,
15(1994)563-571
25. 林奇穎,「檢測潤滑油中鐵顆粒濃度與黏度的整合裝置之性能改善研究」,國立
中山大學機械與機電工程學系碩士論文 (2012)
26. W.S Zhao, “The Application of research on Powder Mixed EDM in rough
machining”, Journal of Materials Processing Technology, 129(2002) 30-33.
27. Y.F Tzeng and C.Y Lee, “Effect of powder characteristics on electrodischarge
machining efficiency”,The International Journal of Advanced manufacturing
Technology, 17(2001) 586-592