本文係以實驗設計法針對M1.2擠壓絲攻之不同製程參數進行實驗，並採用鋁合金AL7075-T651為材料，進行攻牙實驗並針對其結果進行最佳化分析。實驗使用動力計量測攻牙過程中的扭矩與軸向力，並透過電荷放大器及訊號擷取器將訊號放大並轉成電壓訊號輸入至電腦，並利用Labview之人機界面程式監控攻牙過程中的扭矩值大小。接著利用金相研磨機將試片研磨至螺紋孔之中心面後，使用光學顯微鏡拍攝牙型輪廓，採用ImageJ將圖片進行後處理與二值化分析並且計算牙型之面積，進而求得飽牙率。實驗完成後探討改變下孔徑、主軸轉速以及潤滑濃度等製程參數對飽牙率與扭矩之影響。實驗設計則採用二階反應曲面建構的中央合成實驗設計；使用統計軟體Minitab對實驗結果進行統計及變異數分析(ANOVA)，最終建立最大牙型飽牙率及最小扭矩值之迴歸模型。本文除了討論各因子之變動對品質特性的影響，也將探討最佳之製程參數設計，以達到降低扭矩值及提高飽牙率之目的。最後對最佳化結果進行實驗驗證，其結果顯示模型有較為準確的預測性，且最佳化參數可有效的使攻牙過程變得更有效率。;In this study, the design of experiments is used to conduct experiments on different process parameters of the M1.2 forming tap. The aluminum alloy AL7075-T651 is used as the material to conduct the tapping experiment, of which the data were employed for analysis of processing optimization at the same time. The torque and thrust force in the tapping process are measured by a dynamometer. The signal is amplified by a charge amplifier and converted into a voltage signal at the same time. After amplifying, the signal is inputted to a computer. The results of the experiment are monitored and saved by the brain-machine interface code which was coded by Labview. When the setting of the experiment is completed, we are trying to figure out the effect of the process parameters such as lower aperture, the speed of the rotation, and the concentration of the lubrication on the filled rate and torque. The test pieces are ground to the center surface of the threaded hole by a metallographic grinder. The images of the thread profile are taken by an optical microscope contour, which was used to binarize with ImageJ for calculating the area of the thread profile. After that, the filled rate can be calculated. The central composite design (CCD) method, a type of second-order response surface methodology, is used in the experiment. Analysis of variance (ANOVA) based on the experimental results established the regression equation of torque and thread fill rate by using Minitab software. According to the effects of factors on process parameters, figure out the optimal design to increase thread fill rate, and reduce torque in the tapping process. Furthermore, the optimized result is validated by the experiments, it shows that the analysis model has certain accuracy on the internal thread process. The optimized result can make the tapping process more efficient.
