多點成形技術(MPF)為模面由許多多點衝頭排列組成，可藉由調形螺桿帶動調形塊，用以調整衝頭高度，達到可變模面的效果。此成形技術改善傳統單一模具僅能生產單一產品的情況，因此可適用於多種尺寸造型及生產數量的金屬板金生產，這些優點大幅減少了模具開發成本。本研究設計之多點成形模具包含ø10mm、ø15mm、ø20mm等3種衝頭尺寸，成形方式為「固定衝頭」即板金成形之前預先將衝頭調整到指定高度位置，並配合「多點模具成形」即上下模具均為固定衝頭進行衝壓；調形方式為調形塊由固定板以及四周環繞調形塊彼此限制平面方向自由度，保留調形塊及衝頭垂直方向上下移動，同時藉由游標卡尺測量該多點衝頭所需位移量以協助調形模面，藉此達到調整不同曲率半徑模面效果。為了解並預測該模具之成形性，研究中使用CAD軟體SolidWorks建立分析模型，並使用CAE軟體ABAQUS分析板金成形過程:顯式方法(Explicit dynamic)模擬衝壓狀態，隱式方法(Implicit；General static)模擬板金回彈狀態；亦使用7075-O退火鋁合金實際進行衝壓成形實驗，並以3D掃描成形之試片以生成曲面點雲，再以C2M方式與目標形狀比較二者之差異性。研究中藉由實驗設計(DOE)田口方法探討在4個不同因子(超彈性材厚度、超彈性材硬度、衝頭大小、曲率半徑)以及3個不同水準下對於成形造成之形狀誤差的影響並找出最佳製程參數組合，結果顯示模擬分析與成形實驗二者最佳製程組合均為6mm的超彈性材料、PU Shore A90超彈性材料硬度、ø20mm的衝頭大小、300mm曲率半徑，分析最佳製程預測值為11.0958dB、實驗最佳製程預測值為10.4738 dB；經由變異數分析比較各項因子對形狀誤差的影響程度，模擬分析結果其貢獻率由高到低為:超彈性材厚度、超彈性材硬度、衝頭尺寸、曲率半徑；經由成形實驗結果其貢獻率由高到低為:超彈性材硬度、衝頭尺寸、曲率半徑、超彈性材厚度；造成二者貢獻率不同原因研判為:分析中對稱邊界，無法在成形實驗中完全相同，成形過程皺褶處會往衝頭間空隙移動，造成板件些許偏轉。其次超彈性材料機械性質為引用參數，可能造成些許誤差。

Multi-Point Forming (MPF) which die surface is replaced by a pair of matrices of punches. The relative positions of the punches can be varied to suit the requirements. This forming technology improves the conventional die that can only produce single product. It combines the advantages: variable production quantity, variable product sizes and shapes. Moreover it can reduces the die development cost. In this research, the punches of MPF die can change to three different sizes: ø10mm, ø15mm and ø20mm. The forming method is “Relative fixation” which means adjusting the punch to specific position and height before the forming process. The punches adjusting method is that the adjusting block is fixed by fixing plate and surrounding blocks. The punches are limited in plane direction so that they can remain movement in vertical using adjust lead screw and make punches moving up and down. The punches displacement positions are measures by Vernier caliper and to form the die surface. In order to predict the shape of the formed panel. This research use the CAD software SolidWorks to create the analytical model, and use CAE software ABAQUS to simulate the form ability. The explicit method (explicit dynamic) simulate stamping process and implicit method (general static) simulate the spring back process of the panel. Regarding the experiment results, the aluminum alloy 7075-O was used to do the stamping test. The formed panel was scanned by 3D scanner to generate the point cloud model to compare with target shape in C2M method. The Taguchi method of Design of Experiments (DOE) was used to investigate the effect of the 4 different factors (hyperelastic thickness, hyperelastic hardness, pin tip size, radius of curvature) and 3 different levels on shape error and find out the optimal parameter. The results show that the simulation analysis and forming experiment which optimal processes are 6mm hyperelastic material, PU Shore A90 hyperelastic material, ø20mm pin tip and 300mm radius of curvature. The optimal process prediction of simulation analysis is 11.0958 dB and the forming experiment is 10.4738 dB. The factor effect of shape error is compared from the Analysis of Variance (ANOVA). The contribution rate of simulation analysis from high to low is: hyperelastic material thickness, hyperelastic material hardness, pin tip size, and radius of curvature. The contribution rate of forming experiment from high to low is: hyperelastic material hardness, pin tip size, radius of curvature, and hyperelastic material thickness.

摘要......i
Abstract......ii
誌謝......iii
目錄......iv
表目錄......vi
圖目錄......vii
符號說明......ix
第一章 緒論......1
1.1 前言......1
1.2 研究動機與目的......2
1.3 研究方法與步驟......2
1.4 文獻回顧......4
1.5 論文總覽......8
第二章 基礎理論......9
2.1 多點成形模具衝頭、多點衝頭......9
2.1.1 多點成形模具......9
2.1.2 衝頭種類......9
2.1.3 多點衝頭排列種類......10
2.2 多點衝頭定位調形方式......11
2.2.1壓緊式......11
2.2.2液壓式......13
2.2.3機械驅動式......14
2.3 成形方式......14
2.4 多點成形缺陷......15
2.4.1 凹陷......15
2.4.2 皺褶......16
2.4.3 回彈......16
2.5 有限元素數值方法......17
2.5.1 顯式方法......17
2.5.2 隱式方法......18
2.6 實驗設計-田口法......19
2.6.1 實驗設計......19
2.6.2 田口法......20
2.6.3 變異數分析(ANOVA)......23
2.6.4 分布與最佳製程參數組合預測值信賴區間......25
第三章 研究方法......26
3.1 田口式直交表建立......26
3.2 衝頭位移與調形......27
3.3 機械材料拉伸試驗......29
3.4 有限元素分析......31
3.4.1 有限元素分析規劃流程......31
3.4.2 分析模型材料設定......32
3.4.3 邊界、網格設定......33
3.4.4 時間位移設定......34
3.4.5 求解器設定......35
3.5 衝壓成形實驗......36
3.6 板金形狀誤差量測......39
3.6.1 板金3D幾何掃描......39
3.6.2 有限元素分析板金幾何......40
3.6.2 板金幾何比較......41
第四章 機械驅動式多點成形模具設計與開發......42
4.1 機械驅動式多點成形模具設計......43
4.2 多點衝頭部件以及排列方式......44
4.2.1 衝頭......44
4.2.2 調形螺桿與調形塊......44
4.2.3 多點衝頭排列方式......45
4.3 多點衝頭作動與調形......45
4.4 成形方式......46
第五章 結果與討論......48
5.1 AA7075-O機械性質......48
5.2 多點衝頭負載......50
5.1 有限元素分析之結果......51
5.4.1 模型有效性評估......51
5.4.1 板金缺陷......52
5.2 有限元素分析之幾何誤差......54
5.3 衝壓成形實驗結果之幾何誤差......57
5.4 田口法分析......59
5.4.1 模擬分析板金結果......59
5.4.2 衝壓成形實驗結果......63
第六章 結論與建議......66
6.1 結論......66
6.2 建議......67
參考文獻......68
附錄......71
Extended Abstract......80
Abstract......80
1. Introduction......81
2. Research method......81
2.1 Taguchi orthogonal table......81
2.2 FEA modeling of MPF die......82
2.3 Forming experiment......85
2.3 Shape error measurement......86
3. Result and discussion......86
3.1 Shape error of FEA result......86
3.2 Shape error of forming experiment result......88
4. Conclusion......90

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