臺灣博碩士論文加值系統

有鑑於金屬端部成形製程上，依所需產品得開發相對應的模具做生產利用，然而無論是開發新的模具，亦或是模具在使用後發生損壞而必須修護下，均得支出一定費用。因此，本研究以使用一種無需利用模具即可使金屬棒材端部受成形之方法。首先給定金屬棒材端部幾何，並使用三組線圈移動速度，依文獻公式求出材料所受之軸向抽製速度變化，輸入至有限元素模擬軟體。高週波感應線圈能對材料做局部加熱，因高溫條件下使材料加熱處降伏強度降低，同時給予棒材軸向抽製負荷使材料受頸縮成形，直至斷裂後觀察其成形輪廓。據控制抽製速度變化與線圈移動速度，得以完成棒材之成形幾何。在線圈移動速度為0.5 mm/s以及所對應之抽製速度變化對成形影響，可獲得較符合目標之三組端部幾何曲線。藉觀察感應線圈位置與頸縮變形處，可發現在線圈移動速度為0.2 mm/s與0.5 mm/s時，棒材流入線圈之出口位置與最大頸縮變形處為一致關係，此種現象則正是端部得以受控制之因素之一。

In view of forming the end of metal bar, product can be manufac-tured by its corresponding dies. However, to manufacture the new die or repair the die which need to cost. This study use the dieless drawing which is made the end of metal bar without any mold. To Find the variable drawing velocity by given a metal bar geometry, and use three fixed velocity of heating coil. To set the velocity to FEM, the material is heated with setting high frequency induction heating. At higher tem-perature that the yield strength of material be decreases, then giving an axial force that material is necked, until the material occurs ductile fracture. By control the fixed velocity of heating coil and the variable drawing velocity, the end of metal bar geometry can be obtained. When velocity of heating coil with 0.5 mm/s and its corresponding variable drawing velocity for dieless drawing, the end of metal bar can be man-ufactured better curve. In the velocity of heating coil is 0.2 mm/s and 0.5 mm/s, the coils position and deformed zone which both position are consistency.

謝辭 i
摘要 ii
Abstract iii
目錄 iv
圖目錄 vi
表目錄 xi
符號表 xii
1 前言 1
1.1 文獻回顧 2
1.1.1 端部成形相關製程 2
1.1.2 無模具抽製法 6
1.1.3 文獻回顧結語 19
1.2 研究目的與方法 19
2 實驗規劃與設定 21
2.1 研究設計 21
2.2 幾何參數設定 22
2.3 有限元素模擬 28
2.3.1 網格建構 28
2.3.2 材料性質 29
2.3.3 邊界條件設定 30
2.4 實驗設定 32
2.4.1 運動控制 33
2.4.2 高週波感應加熱設備 35
2.4.3 量測與資料擷取 36
2.5 研究流程 38
3 結果與討論 40
3.1 模擬成形結果 40
3.1.1 溫度900 °C模擬成形結果 40
3.1.2 溫度1000 °C模擬成形結果 44
3.2 線圈運動與截面減縮關係 47
3.3 實驗與模擬成形結果 50
4 結論與展望 61
5 參考文獻 63
附錄A 幾何曲線建立 66
附錄B 截面積減縮率 70
附錄C 抽製速度計算 71
附錄D 不同端部幾何長度之應用 76
附錄E DEFORM內建材料性質 82
附錄F 模擬與實驗加熱設定 84
附錄G 延長成形時間結果 86
附錄H 量測圖片 87

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