臺灣博碩士論文加值系統

中間溫度鍛造雖然在成形精度較熱鍛為高，而成形性較冷鍛為佳，但其模具卻相對受到高溫及高壓力之作用，因此模具磨損是影響其量產性之關鍵因素之一，有必要對此問題做一研究。加上近年來應用有限元素法，以電腦數值模擬來分析規劃製程已十分普遍，可分析出如胚料、模具之應力、溫度、應變率…等，如果能將這些資料與磨耗理論結合，便能夠預測溫鍛模具之磨耗情形。
本文主要目的為如何利用數值模擬之方法，應用於溫鍛模具磨耗分析。研究方法為利用有限元素分析軟體DEFORM-3D進行熱傳、收斂性及非恆溫圓環壓縮試驗分析，並透過線上量測裝置的記錄與比對，修正模擬係數。並採用適合於溫鍛製程之磨耗模式，規劃進行磨耗試驗，求出磨耗係數；最後以模擬一工業實例，結合磨耗模式，分析模具磨耗之特性。
本研究有三項主要貢獻：(1)提出線上溫度、負荷量測裝置之設計方法與製作；(2)建立適合於溫鍛製程之磨耗模式與係數；(3)建立數值模擬於溫鍛模具磨耗分析之方法。

Warm forging process has better forming precision than hot forging process and has better formability than cold forging process. But warm forging die suffers high temperature and high working pressure. So die wear is one of the major factors which affect quantity production. The study of wear problem is necessary. The computer-aided engineering (CAE) has been widely used since the development of the finite element analysis and the rapid progress of the computer technology. For most computer simulation of forging process simulation, process variables such as stress, strain rate, temperature etc. are analyzed. If those simulation data are combined with the wear theory, the wear of the die can be predicted.
The purpose of this research is applying numerical simulation to wear prediction of warm forging die. FEM code DEFORM-3D was used to perform heat transfer and convergence analysis and non-isothermal ring compression tests simulation. The results were compared with the data measured by designed measuring device. And according to a suitable wear model, wear test was planned and carried out. At last, an industrial example was simulated and analyzed with the wear model. The wear condition of die was predicted.
There are three major contributions in this research: (1)The temperature and load measuring devices were designed and implemented; (2) A suitable wear model for warm forging process were proposed; (3) The method of using numerical simulation for wear analysis of warm forging die were developed.

第一章前言..............................................1
1-1 緒論...............................................1
1-2 文獻回顧...........................................1
1-3 本文研究範疇.......................................5
第二章磨耗特性之討論....................................7
2-1 模具磨耗型式.......................................7
2-2 模具磨耗參數分析..................................10
第三章實驗方法.........................................14
3-1 實驗目的..........................................14
3-2 實驗設備與材料....................................16
3-3 線上溫度量測方法設計及製作........................22
3-4 線上應力量測方法設計及製作........................24
3-5 熱傳實驗..........................................25
3-6 非恆溫圓環壓縮試驗................................26
3-7 磨耗試驗規劃......................................27
第四章電腦模擬解析.....................................29
4-1 有限元素法於塑性成形之理論分析及應用..............29
4-1-1 FEM 於塑性成形之應用.........................29
4-1-2 塑性成形之FEM 力學模式分析...................30
4-1-3 DEFORM 模擬軟體簡介..........................33
4-1-4 DEFORM 的使用流程............................36
4-2 模擬條件規劃......................................38
4-2-1 CAD模型建立..................................39
4-2-2 收斂性分析...................................40
4-2-3 熱傳分析模擬.................................42
4-2-4 非恆溫圓環壓縮試驗模擬.......................43
4-2-5 工業實例模擬.................................44
第五章結果與討論.......................................49
5-1 塑流應力行為特徵..................................49
5-2 熱傳模擬分析......................................51
5-3 非恆溫圓環壓縮試驗................................55
5-3-1 實驗結果.....................................55
5-3-2 有限元素分析結果之比較.......................58
5-4 磨耗試驗..........................................63
5-4-1 實驗結果.....................................63
5-4-2 磨耗模式參數之建立...........................73
5-5 數值模擬結果與模具磨耗之關係建立......................74
第六章 結論與建議.........................................77
6-1 結論..................................................77
6-2 建議..................................................78
參考文獻..................................................80
附錄......................................................84

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