本研究係以導電高分子作為工具電極之新式鏡面加工法。導電高分子已知的好處有導通微電流、容易加工成型的特性、具有夾持磨粒之能力與具有優秀的抗磨耗性等優勢。研究中探討磨粒粒徑、加工時間、電解液濃度、加工電流與加工負荷等參數對SUS-304 不鏽鋼表面粗糙度與移除深度之影響。
當實驗條件為磨粒粒徑3 μm、電解液濃度10 wt%、加工電流10~20 mA 與加工負荷10 N 下，加工3 分鐘後可將工件原始表面粗糙度之最大高度Rmax 由1.4 μm降至0.17~0.24 μm，且在最佳條件下表面粗糙度之中心線平均粗糙度Ra 更為7.897nm。此外，當電解液濃度為10 wt%時，實驗結果顯示加工電流有一理想範圍存在。依據表面輪廓與SEM 照片，三個加工區可分為：(1)機械拋光區、(2) 電解擦光區與(3) 過度腐蝕區。為了達成高品質之鏡面，加工區必須確保在電解擦光區內。

A novel mirror finishing method using a conductive polymer as the tool electrode is presented. It has been known that the conductive polymers have many advantages, such as to conduct a micro-current, to be easily processed into various shapes, to hold abrasives, and to have an excellent wear resistance. The effects of particle size, machining time, concentration of electrolyte, working current, and load on the surface roughness and the removal depth of SUS-304 stainless steel are investigated.When the operative parameters are set for the particle size of 3 μm, the concentration of electrolyte of 10 wt%, the working current ranged from 10 to 20 mA, and the load of 10 N, the surface roughness Rmax, which originally is 1.4 μm, can be reduced to 0.17~0.24 μm after the machining time of 3 min. The surface roughness Ra can be achieved to 7.897 nm under the optimal condition. In addition, experimental results show that there is an optimal region of the working current at the concentration of electrolyte of 10 wt%. According to the surface profiles and SEM micrographs, three machining regions can be classified as (1) the mechanical polishing region, (2) the electro-chemical buffing (ECB) region, and (3) the excessive corrosion region. To achieve a high-quality mirror-like surface, the machining region must be operated at the ECB region.

論文審定書…………………………………………………………………………….... i
誌謝……………………………………………………………………………………... ii
中文摘要……………………………………………………………………………….. iii
英文摘要……………………………………………………………………………….. iv
總目錄…………………………………………………………………………………... v
圖次…………………………………………………………………………………… viii
表次……………………………………………………………………………………. xii
第一章 緒論……………………………………………………………... 1
1.1 研究動機……………………………………………………………………………. 1
1.2 文獻回顧……………………………………………………………………………. 2
1.2.1 電解加工之文獻……………………………………………………………. 2
1.2.2 電解拋光之文獻…………………………………………………………… 3
1.2.3 電解擦光之文獻…………………………………………………………… 4
1.2.4 電解擦光之各種加工工具的發展………………………………………… 7
1.3 研究目的…………………………………………………………………………... 10
第二章 加工原理………………………………………………………. 12
2.1 電解加工原理……………………………………………………………………... 12
2.2 電解拋光原理……………………………………………………………………... 13
2.3 電解擦光原理……………………………………………………………………... 14
2.4 導電高分子聚合物………………………………………………………………... 17
2.5 電解擦光之主要影響因子………………………………………………………... 18
第三章 實驗設備與實驗方法…………………………………………. 19
3.1 實驗設備………………………………………………………………………….. 19
3.1.1 往復摩擦式鏡面加工試驗機系統………………………………………… 19
3.1.2 資料蒐集分析與訊號量測設備…………………………………………… 21
3.2 實驗材料之特性與幾何形狀…………………………………………………….. 23
3.2.1 工件材料之特性與幾何形狀……………………………………………… 23
3.2.2 電解液的選擇……………………………………………………………… 24
3.2.3 工具電極…………………………………………………………………... 26
3.3 前處理…………………………………………………………………………….. 33
3.3.1 不銹鋼工件………………………………………………………………... 33
3.3.2 工具電極…………………………………………………………………... 34
3.3.3 壓克力槽體………………………………………………………………... 34
3.4 實驗條件設定…………………………………………………………………….. 35
3.5 實驗步驟………………………………………………………………………….. 36
3.5.1 硝酸鈉(NaNO3)水溶液之調配……………………………………………. 36
3.5.2 實驗流程…………………………………………………………………... 36
3.5.3 不銹鋼工件之量測………………………………………………………... 37
3.5.4 電流波形之量測…………………………………………………………... 39
第四章 實驗結果與討論……………………………………………….. 40
4.1 前導實驗………………………………………………………………………….. 40
4.1.1 純磨粒作用………………………………………………………………... 40
4.1.2 純電解作用………………………………………………………………... 45
4.2 電解與磨粒複合作用…………………………………………………………….. 50
4.2.1 磨粒粒徑………………………………………………………………….. 50
4.2.2 加工時間………………………………………………………………….. 55
4.2.3 電解液濃度……………………………………………………………….. 60
4.2.4 加工電流………………………………………………………………….. 65
4.2.5 加工負荷………………………………………………………………….. 74
第五章 結論與未來研究方向………………………………………... 81
5.1 結論……………………………………………………………………………….. 81
5.2 未來研究方向…………………………………………………………………….. 82
參考文獻…………………………………………………………………. 83

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