臺灣博碩士論文加值系統

摘要
由於對冷輥壓成型產品品質提高之要求，必須深入了解相關彎曲及伸展等製程之製程參數，對產品長度及厚度尺寸等之影響。為了得到好的冷輥壓製品品質，因此必須做好整個製程的外形變化預估。本文利用電腦輔助模擬軟體DEFORM-3D來分析模擬厚圓管冷輥壓成型之輪廓外形，以及可用來預估輥壓成型中的應力及應變與破壞情形之產生。本研究成果可成功改善實際冷輥壓成型之製程，尤其是當採用新型式或不同材質時，可節省不少試模成本及增加效率。

Abstract
Increasing demands for cold roll forming production of high quality with a pass sequence of bending and stretching deformation during breakdown material, process parameters related to dimension change in thickness and length need well understanding. In order to obtain good quality of cold roll forming parts, it is necessary to predict the shape variation from the initial pass to the final strip. In this paper, a computer aided simulation program DEFORM-3D was used to study cold roll forming profile analysis and simulation DEFORM-3D software. This software has been used to predict hardness, residual stresses, effective strain and fracture in the roll forming process. The results obtained in this thesis will help improve both the simulation process and the actual cold roll forming process especially when new or different metals are being introduced

TABLE OF CONTENTS
摘要 I
Abstract II
Acknowledgments III
Table of contents IV
List of Figures VI
List of Tables VIII
CHAPTER 1 1
1.1 Background and Overview 1
1.1.1 Roll Forming 1
1.1.2 Application of Software DEFORM-3D 2
1.2 Objective 5
1.3 Outline of Thesis 5
CHAPTER 2 6
2.1 Literature Review 6
2.2 Tooling 9
2.3 Process Parameters Of Roll Forming 9
2.3.1 Roll Design Process 9
2.3.2 Operating Parameters 14
2.3.3 Quality and Accuracy 14
2.4 Roller Geometry 15
2.4.1 Forming Rolls 15
2.4.2 Flower Design 15
2.4.3 Roll Design of an Aluminum Tube 16
CHAPTER 3 20
3.1 Rigid-Plastic Finite Element Method 21
3.2 Second-Degree Polynomial Regression Method 24
3.3 Determination of Buckling Limit of Strain for Tube, Kiuchi's Experiments 26
3.4 Velocity Field 29
3.5 Element Strain-Rate 31
3.6 Elemental Stiffness Equation 32
CHAPTER 4 34
4.1 Object Geometry 34
4.2 Process Parameter 36
4.3 Numerical Simulation of Cold Roll Forming Process 39
4.3.1 Model Definition 39
4.3.2. Workpiece Meshing 40
4.3.3. Workpiece Material 42
4.3.4 Rotational Movement 42
4.3.5 Assign Boundary Conditions. 44
4.3.6. Simulation Controls 46
4.3.7 Step Controls 47
4.3.8 Friction Parameter 48
4.4 Running Simulation 49
CHAPTER 5 57
5.1 Program Verification 57
5.2 Investigation Results 57
CHAPTER 6 71
REFERENCES 72

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