切削進給率優化技術

摘要：隨著航空產業走向節能、省碳的大趨勢，其零組件必須兼具輕量、安全、可靠等嚴苛要求，多數航太零組件廠商會將整塊胚料直接加工，一個工件的切削移除量往往超過九成，且零件形狀極其複雜。

要完成這樣複雜的工件，不僅牽涉到工件切削位置的精準度，刀具的進給速度和負載更是關鍵。在過去，都是仰賴資深工程師、老師傅的經驗，做壞了一件又一件工件，在失敗中找答案，才能完美切削出複雜的曲面結構件。

工研院所開發SpeedPro製程優化軟體，結合切削動力學與最佳化方法，可協助人們更精確地駕馭工具機。SpeedPro會根據不同工件的材質、形狀，計算出加工路徑上每點的刀具與工件受力狀況，規劃出最佳化的製程參數，達到保護高價零組件及發揮製造設備最大產能的目的。

最典型的應用案例，就是航太產業中的金屬渦輪葉片(blade)。只要在工具機導入SpeedPro軟體，便可在葉片首次加工前，完整預測加工路徑之切削力與主軸負載等變化，進而在加工路徑規劃時，藉由調整參數控制切削力道，確保加工過程的效率及穩定性，讓渦輪葉片等複雜工件在首次加工就能完美呈現，進而改善現有製造產業之生產效率。

Abstract：The aerospace industry's current trend to reduce carbon emissions has created a demand for lighter, safer and more reliable components. Nevertheless, existing modes of processing workpiece often result in a 90% removal rate, and the parts have extremely complex geometric features.

Manufacturing such complex components calls for accurate calculations of the cutter locations. The keys to achieving this lie in the cutter’s feedrate and loading force. In the past, senior engineers and skilled machinists relied on their experiences gained through numerous trial-and-errors to produce the perfect curve and complex structure.

ITRI's SpeedPro machining optimization software combines cutting dynamics and optimization methods to help users control the machine tool more accurately. Taking into account the workpiece's material and geometric features, SpeedPro can calculate the cutting force along each point of the tool path, thereby providing an optimum machining process. This helps ensure the safety of expensive components and also maximizes the machine's productivity.

The SpeedPro’s most typical application is its production of metal turbine blades in the aerospace industry. Deploying the software onto the machine tool prior to the blades' initial processing, users can make comprehensive tool path predictions, including cutting force and spindle load. During the simulation stage, users can modify the tool path’s cutting force through the software’s control panel and further ensure the efficiency and stability of the machining process. SpeedPro makes it possible for complex components such as the turbine blade to have near perfect features upon first production, therefore improving the machining industry's overall productivity.

關鍵詞：智能化工具機、刀具路徑擷取、切削力優化
Keywords：Intelligent Machine Tools, Tool Path Acquisition, Cutting Force Optimization

前言
由於航空產業的輕量化、節能與省油趨勢，及航太零組件的安全性與可靠度要求，航太零組件廠商常用整塊胚料直接加工，多數工件的切削移除量超過九成，且零件形狀複雜更造成加工時間較長，且為滿足複合曲面的薄形結構件要求，多數航太零組件廠商更會採用高價的五軸加工機，可能衍生的設備成本亦較高；此時，有經驗的技工便相形重要，可以用程式設計來提升生產效率，並用經驗值預應碰撞問題，以避免昂貴機台與刀具損失。

某公司為航太用渦輪葉片的專業廠，每年營業收入超過百億元新台幣，必須仰賴有經驗的技工透過程式設計，才能縮短加工時間並避免撞機，有效提升生產效率且降低設備損失。

近年來，新興國家（如中國大陸、印度）的快速崛起，讓此公司面臨低價競爭與訂單移轉的競爭壓力，有經驗的技工陸續退休，對此公司而言又是另一個頭痛問題。