臺灣博碩士論文加值系統

高長寬比矩形引伸產品應用領域十分廣泛，當中更常被應用於工業中電池容器或電子零件外殼。而這類矩形杯引伸產品通常因為其短邊與高度的比值較大，無法由單一道次完成加工，因此，勢必須進行多道次引伸加工。本研究嘗試結合反向再引伸的加工技術，利用成形時對於產品的內、外壁交互作用，可減緩內、外壁累積應力的特徵，藉以改善非對稱形狀且具高長寬比產品的成形性，進而達到減少引伸次數的目的。
本研究使用Dynaform有限元素分析軟體輔助模擬引伸加工，針對SUS304不銹鋼厚度0.8 mm板材，進行矩形杯多道次引伸成形參數對引伸成形高度、成品厚度分佈以及材料流動狀態之影響，並搭配實際開發模具與實驗，近一步驗證分析結果的可靠性，以做為往後矩形杯多道次引伸加工模具設計之參考。
研究結果顯示，反向再引伸模具成形性優於(h2=37.3 mm)直接再引伸模具(h2=27.8 mm)，且因邊圓角輪廓距離(X2=5.02 mm)較大，引伸次數可減少(3 Stage)；當胚料在引伸過程中發生起皺現象，會使胚料與模面接觸不均，起皺部位無法有效流入模穴進而發生破裂，在不發生起皺現象的條件下。使用圓胚料成形時，最大可成形直徑為100 mm，成形高度為41.54 mm；引伸時矩形杯直邊常需取成圓弧，當長邊圓弧半徑(RX1=191.48 mm、RX2=187.85 mm)越大，矩形杯則因長、短邊長度差異過大而造成金屬流動不均，在相同成形高度時材料在距胚料邊緣移動距離差距較大，變薄率較高；過小的沖頭圓角半徑(Rp1=0.8 mm、Rp2=1.6 mm)容易造成板材在角隅部外側受較大之拉伸應變，使材料過度薄化而發生破裂的現象。於實際引伸成形實驗成品的厚度分佈趨勢以及破裂位置，實測值均與模擬分析結果吻合。

Rectangular cups with high aspect ratio are widely used in an industrial battery container or electronic part case. Such rectangular cups usually have large ratio of height to the length of the short side and the multi-stage drawing stage instead of a single drawing stage is required to successfully forming processes. A reverse re-drawing processing, which would reduce the forming stress by the interaction of the inner and outer walls of the product during forming, is applied to improve the formability of rectangular cups with high aspect ratio to reduce the stages of drawing.
A software of Dynaform finite element analysis is used to simulated drawing processing in this study to investigate parameters of drawing for the stainless steel sheets, SUS304, of thickness 0.8 mm which would influence the distribution of the thickness, the drawing height and the material flow state. A set drawing die manufactured the experiments of drawing are conducted to verify the realities of the results of simulation which is used as a reference for the multi-stage drawing processing die design of the rectangular cup.
The simulation results indicate that the formability of the reverse re-drawing, which drawing height, h2, is 37.3 mm, is better than that of, h2 , 27.8 mm. And the stage of drawing can be reduced to 3 stage due to the larger edge contour distance, X2, is 5.02 mm. Wrinkling around the blank sheet during drawing causes uneven contact between the blank sheet and the die surface, so the wrinkle portion material cannot effective flow into the cavity of the die and occurs the crack.
A limit blank diameter designed to drawing of the rectangular cup in this study is 100 mm and the drawing height is 41.54 mm. The straight side of the rectangular cup need to modify to arc during drawing. As the arc of the long straight side of rectangular cup is larger, such RX1 is 191.48 mm, RX2 is 187.85 mm, the larger difference of material flow occurred between the long straight side and short straight side. Therefore the material moving distance from the edge of the blank has a large difference in many axial directions and the thinning rate of products becomes high.
As the punch fillet radius is small, such Rp1 is 0.8 mm, Rp2 is 1.6 mm, the corner portion on the outside is easy to be subjected to the large tensile strain which caused the thinning excessive to occur the crack. Conducted the drawing experiments, the distribution of thickness and ruptured position measured are good agreement with that of the simulation analysis.

摘要
ABSTRACT
誌謝
目錄
圖目錄
表目錄
符號說明
第一章 緒論
1-1 前言
1-2 沖壓成形
1-2-1 加工特徵及應用
1-2-2 優缺點及主要特色
1-2-3 應用領域及產品
1-3 引伸加工基本成形理論
1-3-1 引伸成形理論
1-3-2 矩形杯引伸成形理論
1-3-3 反向再引伸成形理論
1-4 材料性質及塑性變形理論
1-4-1不銹鋼之特性與種類
1-5 文獻回獻
1-5-1 引伸成形文獻
1-5-1 矩形杯引伸成形文獻
1-5-2 反向再引伸成形文獻
1-6 研究動機與目的
1-7 論文架構
第二章 研究方法與模型建立.
2-1有限元素法(Finite Element Method)基本理論
2-1-1分析軟體Dynaform功能介紹
2-1-2 Dynaform用戶自定義材料性質設定
2-2引伸成形模擬模型建立
2-2-1 胚料尺寸及工法規劃
2-2-2 反向再引伸模具介紹
2-3 模擬模型建立與參數規劃設定
2-3-1 模擬模型建立
2-3-2 材料性質設定
2-3-3 模擬參數規劃
2-4 模具設計
第三章 引伸成形模擬結果
3-1 模擬結果之定義
3-1-1 測量方向及位置之定義
3-1-2 材料流動狀態之判斷方式及定義
3-1-3 成形高度之定義
3-2 胚料參數之影響(Blank)
3-2-1 不同圓胚料直徑(Db)對變薄率、材料流動狀態之影響
3-3 第一道次初引伸成形參數之影響(1st Drawing)
3-3-1 不同矩形杯長邊圓弧半徑(RX1)對變薄率、材料流動狀態之影響
3-3-2 不同邊圓角圓角半徑(RC1)對變薄率之影響
3-3-3 不同沖頭圓角半徑(Rp1)對變薄率之影響
3-3-4 不同下模圓角半徑(Rd1)對變薄率之影響
3-4 第二道次再引伸成形參數之影響(2nd Drawing)
3-4-1 再引伸成形方式對變薄率與破裂點主應變之影響
3-4-2 不同邊圓角輪廓距離(X2)對變薄率之影響
3-4-3 不同矩形杯長邊圓弧半徑(RX2)對變薄率之影響
3-4-3 不同邊圓角圓角半徑(RC2)對變薄率之影響
3-4-4 不同沖頭圓角半徑(Rp2)對變薄率之影響
第四章 矩形杯多道次引伸成形實驗與模擬結果之比較
4-1 引伸成形實驗流程
4-2 實驗模具及研究設備介紹
4-2-1 初引伸之引伸成形模具介紹
4-2-2 反向再引伸之引伸成形模具介紹
4-2-3 萬能試驗機
4-2-4 電腦數控線切割機
4-2-5 表面輪廓儀
4-3 引伸成形實驗結果
4-3-1 不同圓胚料直徑於初引伸實驗與模擬之比較
4-3-2 固定壓料板間隙於不同圓胚料直徑於初引伸實驗與模擬之比較
4-3-3 不同圓胚料直徑於反向再引伸實驗與模擬之比較
第五章 結果與討論
5-1 結論
5-2 未來展望
參考文獻
附錄一 矩形杯多道次引伸加工實驗模具

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