基於田口法之五軸複合曲面加工參數辨識與最佳化研究

本研究旨在運用田口實驗設計法（Taguchi Method）針對複雜曲面五軸加工製程進行系統化優化，核心目標在於精確鑑別能平衡表面品質與加工效率的最佳切削參數組合。透過 L9 直交表（Orthogonal Array）設計實驗，有效降低傳統試誤法所需之開發成本與時間，並深入探討主軸轉速、進給率、接觸點參數及切削深度對表面粗糙度（Ra）之物理影響。研究規劃選用四組幾何特徵迴異之桶形刀具，於 100x50 mm 之複合曲面區域進行實證切削。實驗結果顯示，刀具幾何結構對製程穩定性具關鍵主導作用。在區域 B 中，具備較短懸伸之刀具 1（75 mm）展現出優於刀具 2（90 mm）的結構剛性，能於 9000 RPM 高速下維持穩定切削，顯著降低平均粗糙度。在區域 A 中，螺旋角 55° 之刀具 4 相較於 50° 之刀具 3，成功將切削深度之貢獻度從 70.81% 大幅降至 36.73%，將主控因子引導至更具可控性之進給速率（46%），顯著提升了製程強健性。本研究透過訊號雜訊比（S/N Ratio）與變異數分析（ANOVA），不僅確立了各刀具區域之最佳化參數規範，更量化解構了刀具長度與螺旋角對精密加工之物理貢獻。此成果為自動化量產提供了高信賴度之標準化規範，實證田口法在提升工業生產效率與產品品質穩定性上的卓越價值，具備高度產業應用意義。

This study systematically optimizes the 5-axis machining process for complex surfaces using the Taguchi Method to identify the optimal combination of parameters that balances surface quality and machining efficiency. By employing L9 Orthogonal Arrays, this research significantly reduces the development costs and time inherent in traditional trial-and-error approaches while providing a deep analysis of the physical impacts of spindle speed, feed rate, contact point parameters, and cutting depth on surface roughness (Ra). Four sets of barrel tools with distinct geometric characteristics were evaluated within a 100x50mm complex surface area. The experimental findings reveal that tool geometry is a critical determinant of process stability. In Zone B, Tool 1, with a shorter overhang (75mm), demonstrated superior structural stiffness compared to Tool 2 (90mm), maintaining stable cutting performance at high speeds (9000 RPM) and significantly lowering the average roughness. In Zone A, Tool 4, featuring a 55° helix angle, effectively reduced the contribution of cutting depth to process variation—from a dominant 70.81% in Tool 3 (50°) down to 36.73%. This shifted the primary control factor to the more predictable feed rate (46%), markedly enhancing process robustness. Through Signal-to-Noise (S/N) Ratio and Analysis of Variance, this study not only establishes standardized optimal parameter specifications for each tool and machining zone but also quantitatively deconstructs the physical influence of tool length and helix angle on precision manufacturing. The results provide highly reliable standardized protocols for automated mass production, validating the exceptional effectiveness of the Taguchi Method in improving industrial production efficiency and product quality stability, offering significant practical value for manufacturing industries.