臺灣博碩士論文加值系統

現代工業產品設計精密度越來越高，而且產品材料的強度也越來越強，若使用沖壓加工技術來大量生產，材料對於模具的影響提升許多，也進而造成模具的磨耗，為避免因為未察覺的模具磨耗而造成產品變異，如何即時檢測模具磨耗狀況為一重要研究課題，本研究試圖開發一款利用伺服驅動器所接收的電壓變化來檢測模具與沖頭異常的系統，開發過程可分為三個階段，第一階段為利用伺服馬達回饋的扭矩變化來判斷多種磨耗模式沖頭(正常、倒角、缺角、側面磨耗與正面凹口) 對紅銅合金C194與不鏽鋼304等板料進行沖剪的變化現象，並確定檢測機制之可行性，第二階段為使用單一磨耗模式區分磨耗程度之沖頭進行測試，並利用光學顯微鏡觀察其對試片斷面的影響，最後階段則利用上述部分結果之發現撰寫LabVIEW程式配合NI擷取卡抓取驅動器電壓變化以完成檢測系統。研究結果顯示，在沖頭特徵上，當沖頭之刃口與側面沒有磨耗，在沖剪材料時所顯示的扭矩會與正常沖頭扭矩相似，硬質材料會比軟質材料更容易反映出沖頭特徵變化而產生的扭矩，實驗中證明，最能影響扭矩變化的因子是沖頭的特徵，而材料的性質則會影響其改變的幅度。根據上述結果，展開第二階段研究，設定固定的磨耗方式，使沖頭在充滿黑色碳化矽的砂盒中進行磨耗，並制定以1000下為磨耗區間，觀察沖頭在各個區間的變化，並對厚度為0.8mm的304不鏽鋼及冷軋高碳鋼SAE1065進行沖剪。實驗發現，以沖剪不鏽鋼304為例，當沖頭經歷1000次磨耗後，沖頭磨耗深度為100.82um，以此沖頭沖剪板件，扭矩值會上升8.3%，毛邊高度會上升12.5%，模輥區間占比會從16.14%上升為20.77%，顯示沖頭磨耗到一定程度，特徵改變，便會開始對生產造成巨大的影響。最後依照當沖頭異常時會發生沖壓力上升及試片斷裂時間延後的兩個條件進行LabVIEW程式撰寫，檢測系統分為兩個模式，一為初始資料收集，二為抓取現場資料並與初始資料比對，在實驗中運用兩種不同材料的沖剪資料進行比對，並且成功辨別出錯誤，證實了此系統的可行性。

Modern industrial products require greater precision and higher material strength. If stamping is used for mass production, the material affects the choice of die as because the wear is increased. Die wear reduces product accuracy so die wear must be detected in real-time. This study develops a system that uses the voltage variation of the servo drive to detect abnormalities in a die or punch. The study has three parts and two stages. The first stage uses the torque feedback from the servo motor to determine the wear modes. The punch type is normal, chamfer, missing corner, side wear, and front notch. The change for copper alloy C194 and stainless steel 304 after punching and cutting are used to determine the feasibility of the detection mechanism. The second stage uses a single abrasion mode to determine the degree of abrasion and an optical microscope is used to observe the effect on a section of the test piece. These results are used to write a LabVIEW program that uses a NI capture card to determine the voltage variation of servo driver to complete the detection system. The results show that the torque is equal to the normal punch torque when the cutting edge and side of the punch are not worn. Moreover, hard materials produce greater torque than soft materials. This experiment shows that the factor that most affects the torque change is the characteristics of the punch and the material of the workpiece affects results secondly. The second stage of this study uses a single abrasion method to produce punch wear in a sandbox that is filled with black silicon carbide. The wear interval is 1000 cycles to determine the effect of the punch for each interval. The stainless steel 304 and SAE 1065 steel with a thickness of 0.8mm were used to do the test. Results show that the wear depth of the punch will be 100.82um after 1000 cycles of wear. The torque value will increase by 8.3% and the burr height will increase by 12.5% when this wore punch is used. Moreover, the proportion of the die roll interval will increase from 16.14 % to 20.77%, indicating the punch characteristics have a huge impact on work piece. Finally, according to the abovementioned results, the LabVIEW program is written. The device is set up to complete the online wear detection system and proved the feasibility of this system.

摘要................................i
Abstract............................ii
誌謝................................iv
目錄................................v
表目錄..............................viii
圖目錄..............................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
1.4.1 沖壓及磨耗原理.................4
1.4.2 磨耗檢測技術...................5
1.5 論文總覽.........................6
第二章 理論基礎.....................7
2.1 沖壓加工及沖剪原理................7
2.2 沖剪斷面及影響因素................9
2.2.1 沖剪斷面.......................9
2.2.2 沖剪斷面影響因素................10
2.3 磨耗原理.........................11
2.3.1 磨耗類型.......................11
2.3.2 磨耗過程.......................12
2.4 沖壓設備與伺服沖床................13
2.4.1 沖床分類.......................13
2.4.2 伺服沖床與伺服馬達..............15
第三章 研究方法.....................16
3.1 伺服沖床與制動軟體................16
3.2 多樣磨耗模式實驗..................19
3.2.1 模具規劃.......................19
3.2.2 試片及沖頭準備..................20
3.2.3 實驗步驟.......................21
3.3 磨耗程度影響實驗..................23
3.3.1 模具規劃.......................23
3.3.2 試片準備.......................24
3.3.3 磨耗沖頭準備....................25
3.3.4 磨耗程度及斷面量測結果量測.......27
3.3.5 磨耗程度影響實驗步驟.............28
第四章 結果與討論....................30
4.1 多樣磨耗模式實驗...................30
4.1.1 紅銅合金C194沖程................30
4.1.2 不鏽鋼304沖程...................31
4.2 磨耗程度影響實驗...................33
4.2.1 沖頭刃口磨耗深度.................33
4.2.2 扭矩變化........................33
4.2.3 斷面分佈變化(304不鏽鋼)..........35
4.2.4 斷面分佈變化(1065冷軋鋼板).......37
第五章 沖壓模具線上檢測系統...........40
5.1 系統架構..........................40
5.2 判讀方式..........................41
5.3 LabVIEW......................42
5.3.1 人機介面......................42
5.3.2 圖形程式區....................43
5.3.3 實務模擬......................47
第六章 結論與建議....................49
6.1 結論..............................49
6.2 建議..............................50
參考文獻..............................51
Extended Abstract.....................53

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