臺灣博碩士論文加值系統

汽車扣件造型及功能多樣化，零件幾何形狀也隨之複雜化，複雜形狀鍛品在使用單軸鍛造成形時，具干涉特徵之成品將無法脫料拔模，使用 3D 鍛造之合模鍛造機可以提供軸向成形與側向開模動作，以便在上料後，完成複雜形狀鍛造及順利脫模，解決複雜外形鍛件的開模干涉問題，使產品整合性更好、生產流程更簡化。本文提出合模軸向鍛造機之沖頭構型與道次設計方法， 以有限元素法分析其成形性，以一模二沖之製程及模具設計鍛造梅花頭螺栓中段六角凸緣。
本文探討3D合模鍛造預成形與模具設計方法，並以電腦輔助分析評估設計品質，用Solid Works 建構螺絲產品3D並設計鍛造模具，以DEFORM-3D 進行合模成形製程模擬。利用田口法探討不同預成形參數設計，以電腦模擬分析不同設計組合規劃之成形負荷，以望小為品質特徵，進行訊噪比計算及ANOVA回應圖分析,可反應出各個因子不同水準間的差異，以瞭解各因子對成形負荷影響之重要性，並可由田口法獲得最佳化參數組合設計，縮短試模時間與快速掌握成形條件與製程參數。
由田口法預測最佳化參數設計成形負荷為4.314噸，以CAE 模擬最佳化參數組合條件之成形負荷為4.226 噸，與預測值誤差為2.03%，可知田口法之預測具可信度。原始標準設計所需之成形負荷為5.622噸，最佳化設計負荷低於原始標準設計，較標準設計改善約23.2%，可有效減少第二道次成形負荷。設計參數對成形負荷影響之重要性排序前二名分別為六角凸緣對角圓弧及六角凸緣高度，可見圓弧對最終材料充模影響大，而凸緣高度則影響凸緣成形所需沖程及等效應變，以最佳化參數設計可以降低成形負荷以增加沖頭壽命。

The shapes and functions of automobile fasteners are diversified, and the geometrical shape design of the parts are also complicated. The single axial forging machine is not able to eject the forged complex part with geometrical features extruded laterally into the die cavity. The 3D forging machine not only has the longitudinal forging movement, but also has the lateral motion capability to open the die cavity for the ejection of the forged parts. The forging process can be finished smoothly form the billet loading to the forged part ejection, the quality of the forging parts is guaranteed and the forming process is simplified. In this paper, the preform design for the one die two punch clamping die forming machine was proposed, the product for demonstration is the plum head bolt with hexagonal flange at the middle of bolt body.
The preform and die design methods of 3D split die forging were studied in this thesis. The different designs were constructed using Solidworks software and evaluated via the CAE method using DEFORM 3D software. Taguchi method was applied to arrange the design parameters and prepare the input conditions for the CAE simulations. The CAE predicted forging load is the quality index of the Taguchi method, which was converted to the ratio of the signal to noise (SN ratio) and applied to the ANOVA analysis. The significance and the optimum combination of the design factors were obtained via the ANOVA and the response chart analysis, which is helpful for the determination of forming condition and time saving of the die try out.
The forging load obtained by using the optimum design factor combination of Taguchi method was 4.314 tons. The CAE predicted forging load of the confirmation design was 4.226 tons. The predicted force of the Taguchi optimum combination had 2.03% error compared to the CAE simulation with the same forming condition. The standard forging die design required 4.226 tons which is 23.2% higher than the optimum forging die design of the Taguchi method. The proposed design method was able to identify the first two important design factors, the radius at the diagonal edges of the flange and the flange height, respectively. The edge radius will affect material flow at the die filling stage, and the flange height will control the punch stroke and the effective strain of the flange. The lower forging load of the optimum design is also helpful to improve the tool life.

國立高雄科技大學模具工程系碩士班 iii
摘要 iv
ABSTRACT v
誌謝 vii
目錄 viii
表目錄 x
圖目錄 xi
一、 緒論 1
1.1 前言 1
1.2 文獻回顧 2
1.2.1 有限元素法 2
1.2.2 扣件設計製程 3
1.3 研究動機及目的 4
1.4 論文架構 5
二、 研究理論 6
2.1 合模螺栓製程 6
2.1.1 鍛造模具形式分類 7
2.2 鍛造製程 8
2.2.1 鍛造模具型式分類 8
2.2.2 鍛造溫度之分類 8
2.3 塑流應力 9
2.4 田口品質設計法 11
2.4.1 實驗設計 13
2.4.2 實驗參數直交表 13
2.4.3 田口品質預測模式 14
2.4.4 因子選擇 15
2.4.5 實驗方法與參數選擇 15
三、 研究製程規劃 18
3.1 設計流程 18
3.2 CAD幾何建模 18
3.3 製程設計 20
四、 合模模擬設定 23
4.1 創建模型 23
4.2 模擬設定參數 23
4.3 材料性質 24
4.4 網格收斂性分析 25
五、 結果與討論 27
5.1 第二道次成形負荷分析 27
5.2 精鍛成形尺寸驗證 29
5.3 合模力 30
5.4 等效應變分析 35
5.5 應變率分析 36
5.6 等效應力 37
5.7 Damage分析 38
5.8 最佳成形條件分析 39
六、 結論與未來計畫 44
6.1 結論 44
6.2 未來研發方向 44
參考文獻 45

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