臺灣博碩士論文加值系統

對於使用於車用螺帽基於安全上的考量，在使用的時數或年限上極為重要。螺帽在冷鍛成型生產順利之下，尺寸達到指定公差範圍內，產品卻往往在製造過程或是線材不良下，生產出的螺帽會出現不同的表面不連續缺陷，如堆疊、龜裂和表面不連續性的疊裂等，因為不良品將由人工和機器篩選，但往往人工篩選不良品過程中，人員對不良品的認知程度有一定的差異，存在將不良品判定為良品的風險，原因是目前機器篩選在一些光學視角上是沒辦法看出的，必須仰賴人工將不良品挑選出來。

本文將探討該如何正確地判定一顆螺帽是否為不良品，以Ｄ公司生產的特殊螺帽作為實驗研究，生產中和人工挑選的不良品施作液體滲透檢測（Liquid Penetrant Testing，LPT）去有效判定被檢查之產品是否為線材表面不連續性上造成之缺陷，或是一般壓痕且同時建立產品不良品可否放行或是不可放行的標準。由於近年來，對於非破壞檢測與破裂力學理論都有更進一步的探討和文獻可以參考，此論文會以深入探討非破壞檢測的液體滲透檢測法，近一步研究如何在生產中發現螺帽的缺陷而立即進行液滲檢測來分辨產品之缺陷或龜裂造成之原因，將不良品施行管制其避免此不良螺帽裂縫演變更嚴重。

由此論文的結論可發現使用液滲檢驗產品缺陷除了對於費用上節省許多之外，還能夠降低破壞機率和提升可信度並且作為Ｄ公司教育訓練，而達成節省成本與提升檢驗安全的最佳效益。最後探討了如何將生產中的不良品做最精實的液體滲透檢驗方式，並且在有效防止判定上的缺失而製造更多的浪費，藉由螺帽缺陷的認識並建立不良品的可視化依據，作為日後Ｄ公司內部現場師傅，機器和人工篩選的基本教育訓練並且普遍提升不良品的辨識度。

關鍵詞：非破壞式檢測，液滲檢測，表面不連續性

Safety considerations for fasteners used in automotive are significantly important in terms of remaining good conditions and useful life. Nuts are made through cold forging technology to reach the specified tolerant range according to customers’ drawings. In cold forming process, when defective wire material being used, cracked nuts will appear immediately from forming machine, then the external and internal cracks will be 100% screened by humans and machines. However, it is not so economical due to the fact that optical sorting machines might have some blind spots that the cracks will not be seen by the camera. As results, non-good parts will rely on manual sorting where there is a risk of determining the defective parts as good ones by operators when they have different opinions on judging parts. Whereas the good products might be sorted as bad when there is no such obvious cracks standards or appearances that could show to the operators. By doing PT examination to the products, cracks in parts are easily seen by human-eyes.

Liquid Penetrant examination is an important method of Non-destructive testing of materials’ surface discontinuities. However, sometimes the workpiece is covered with rust or burr which makes the material defects as shown in the sectional view, the operators will not see the cracks. Therefore, the first step is always to pre-clean the test piece surface which must be done very thoroughly so that any defects present are open to the surface. Due to the penetrance high surface wetting capability which penetrates into the defects and cracks after several minutes of dwell time. Meanwhile, the test piece surface will be rinsed with water in order to remove the penetrance completely from the surface but leaves it in the crack. Finally, the developer supplied will be put on the surface in order to draw the penetrant out from the crack. Thus, the location of the crack indicated clearly on the surface and this is how the research carried out in practice.

In conclusion, it can be found that the experiment and analysis of this paper is the use of liquid penetration testing for product defects. It can reduce the probability of damage, improve credibility and serve as D company’s internal training to achieve cost savings and improve identifying defects skills. It therefore will bring the best benefits to automotive fasteners in all dimensions. Finally, the research explores how to make the defective product of liquid penetration in inspection method, and effectively prevent the lack of judgment toward the products by understanding the defects of special nuts and establishing the basis for the visualization of defective products.

Keywords: Non-destructive Test、Penetrating test、Surface Discontinuities

摘要……………………………………………………………………………………I
abstract……………………………………………………………………….……II

致謝……………………………………………………………………………………III

目錄……………………………………………………………………………………IV

表目錄…………………………………………………………………………………V

圖目錄…………………………………………………………………………………VI

符號解釋……………………………………………………………………………..IX

一、緒論………………………………………………………………………………1
1.1前言………………………………………………………………………..……1
1.1.1個案公司與製程介紹…………………………………………..……2
1.2 本篇研究流程………………………………………………………………3
1.3 文獻回顧…………………………………………………………………..…4
1.4 研究動機與目的……………………………………………………………7
1.4.1 D公司螺帽成型過程…………………………………………………8
1.4.2 組合件螺帽介紹………………………………………………………9
1.4.3 線材盤元介紹…………………………………………………………12
二、基本理念與文獻探討………………………………………………………14
2.1 非破壞檢測的方法簡介…………………………………………………14
2.2 缺陷形成的原因與種類…………………………………………………14
2.2.1 冶煉生產缺陷…………………………………………………………15
2.2.2 螺帽缺陷介紹…………………………………………………………15
2.2.3 核心產品螺帽缺陷介紹……………………………………………18
2.2.4 液滲透檢測……………………………………………………….……19
2.2.5 液滲透檢測的優缺點……………………………………….………19
2.3 目視檢測原理………………………………………………………………20
2.4 液滲透檢測與毛細作用的關係………………………………………20
2.5 磁力檢測…………………………………………………………………..…22
2.6 黑光檢測法原理…………………………………………………………...23
2.7 螢光水洗液滲檢測……………………………………………………..…24
2.8 鍛造概論……………………………………………………………………..24
2.9 研究概論…………………………………………………………………..…25
2.10 實驗研究的原理……………………………………………………….…26
2.11 實驗研究意義……………………………………………………………...26
三、研究方法…………………………………………………………………………27
3.1 螺帽抽樣……………………………………………………………………....27
3.2 實驗研究方法與流…………………………………………………………28
3.3實驗產品組合件的不良品種類……………………………………...…30
3.4 實驗產品基本實驗設備介紹……………………………………………33
四、實驗……………………………………………………………………………..…44
4.1實驗過程…………………………………………………………………….....44
4.2 實驗發現……………………………………………………………………....45
4.3 實驗深度探討………………………………………………………………...54
4.4結果比較冶金調查報告…………………………………………………….56
4.5 D公司客戶客訴實際案例實驗………………………………………....62
五、結論與未來展望………………………………………………………………..72
5.1 結論………………………………………………………………………….......72
5.2 未來展望…………………………………………………………………….....73
參考文獻 ……………………………………………………………………………......74

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