臺灣博碩士論文加值系統

本文主要是探討單點增量引伸法於鋁合金板材(AA1050)成形之技術，針對圓杯之成形性及成形之極限進行實驗研究；過去的文獻對高傾角的極限之研究，多以深寬比較小的情況為主，本文實驗之例子係以較大之深寬比1：2之圓杯，以多步驟成形的模式來成形傾角較高之成品，探討其圓杯底部之倒圓角限制及表面品質之改善。本文實驗所使用的機台為三軸CNC銑床，主軸裝置成形用的衝頭，在CNC床台上將鋁合金板材固定在自製的夾治具後，執行CNC加工程式，驅動工具頭旋轉及以一定的軌跡使板金成形。成形之刀頭路徑是透過 CAD/CAM軟體產生之步階式刀具路徑。實驗結果顯示本文方法可推測其成形性以及改善成品之幾何誤差和底部的表面品質。

The paper aims to investigate the aluminum sheet metal (AA1050) forming on the formability and the process limit of circular cup by using single point incremental forming (SPIF) process. The literatures of the previous investigation on high-inclined angle part are mostly in low depth-width ratio, while the paper aims to form a circular cup with a depth-width ratio 1:2 by using multi-stage process to investigate the rounding limit and improve the quality of the cup. In this paper, all experiments were performed on a CNC milling machine in which the experimental sheet metal was appropriately fixed in a special designed clamping fixture mounted on the machine table and the punch tool was installed on the machine spindle. After that, forming operation can be executed by the NC commands generated from the designed tool paths data. The experimental results show that the forming limit can be predicted and the quality of the cup bottom can be improved by using present method.

中文摘要 i
英文摘要 ii
誌謝 iii
目錄 iv
表目錄 vi
圖目錄 vii
第一章 緒論 1
1.1 前言 1
1.2 研究動機與目的 2
1.3 文獻回顧 3
1.4 本文架構 5
第二章 單點增量成形相關理論 6
2.1 Sine Law厚度公式 6
2.2 具倒圓角之圓杯引伸厚度 7
2.3 單點增量引伸圓杯刀具路徑建構 13
2.3.1 零件模型建構 13
2.3.1.1 建構零件外形 14
2.3.1.2 建構輪廓曲線 15
2.3.1.3 建構掃掠曲面 16
2.3.2 步階式刀具路徑產生法 16
2.3.3 螺旋式刀具路徑產生法 18
第三章 實驗規劃 21
3.1 實驗儀器及設備 21
3.1.1 台灣麗偉TDC-450三軸切削中心機 21
3.1.2 台灣麗偉LV-300SL三軸切削中心機 22
3.1.3 三菱RA-9 CNC線切割放電加工機 23
3.1.4 2.5D光學量測系統 24
3.1.5 板金材料夾治具 25
3.1.6 實驗用沖頭 28
3.1.7 實驗用板材 29
3.1.8 切削液 30
3.2 實驗步驟及方法 31
3.2.1 實驗步驟 31
3.2.2 實驗規劃 32
3.2.2.1 直線多步驟模式 33
3.2.2.2 曲線多步驟模式 34
第四章 實驗結果與討論 36
4.1 倒圓角圓杯之成形性及其極限 37
4.1.1 直線多步驟模式 37
4.1.2 曲線多步驟模式 44
4.2 厚度分佈 46
4.2.1 直線多步驟模式 48
4.2.2 曲線多步驟模式 53
4.3 深度誤差 57
4.3.1 直線多步驟模式 58
4.3.2 曲線多步驟模式 60
4.4 圓杯底部品質改善 61
4.4.1 直線多步驟模式 63
4.4.1.1 方法一 63
4.4.1.2 方法二 65
4.4.2 曲線多步驟模式 67
4.4.2.1 方法一 67
4.4.2.2 方法二 68
第五章 結論與未來展望 70
5.1 結論 70
5.2 未來展望 71
參考文獻 72
附錄
符號彙編 75

[1] J. Verbert, B. Belkassem, C. Henrard, A.M. Habraken, J. Gu, H. Sol, B. Lauwers, J.R. Duflou, "Multi-Step Toolpath Approach to Overcome Forming Limitations in Single Point Incremental Forming," Int J Mater Form, Vol. 1, Suppl. 1, 2008, pp. 1203–1206.
[2] I. Cerro, E. Maidagan, J. Arana, A. Rivero, P.P. Rodr’ıguez, "Theoretical and Experimental Analysis of the Dieless Incremental Sheet Forming Process," Journal of Materials Processing Technology, Vol. 177, 2006, pp. 404–408.
[3] J.R. Duflou, J. Verbert, B. Belkassem, J. Gu, H. Sol, C. Henrard, A.M. Habraken, "Process Window Enhancement for Single Point Incremental Forming through Multi-step Toolpaths," CIRP Annals - Manufacturing Technology, Vol. 57, 2008, pp. 253–256.
[4] S. Matsubara, "A computer numerically controlled dieless incremental forming of a sheet metal," Journal of Engineering Manufacture, Vol. 215, 2001, pp. 959-966.
[5] M. Ham & J. Jeswiet, "Single Point Incremental Forming and the Forming Criteria for AA3003," CIRP Annals - Manufacturing Technology, Vol. 55, Issue 1, 2006, pp. 241–244.
[6] M. Skjoedt, N. Bay, B. Endelt, G. Ingarao, "Multi Stage Strategies for Single Point Incremental Forming of a Cup," Intermational Journal of Material Forming, Vol 1, Suppl. 1, 2008, pp. 1199-1202.
[7] M Skjoedt, M B Silva, P A F Martins, and N Bay, "Strategies and Limits in Multi-Stage Single-Point Incremental Forming," Journal of Strain Analysis for Engineering Design, Vol. 45, 2010, pp. 33-44.
[8] M. Beatriz Silva, Martin Skjoedt, Niels Bay and Paulo A. F. Martins, "Multistage Single Point Incremental Forming," Proceedings of the Congress on Numerical Methods in Engineering, Vol. Paper ID57 , 2011.
[9] R. Malhotra, A. Bhattacharya, A. Kumar, N.V. Reddy, J. Cao, "A New Methodology for Multi-pass Single Point Incremental Forming with Mixed Toolpaths," CIRP Annals - Manufacturing Technology, Vol. 60, Issue 1, 2011, pp. 323–326.
[10] 楊浩、石穆征、盧永華、陳大智、李經綸，「軸對稱杯單點增量成形刀具路徑與板厚分佈之研究」，精密機械與製造科技研討會論文集，2012，第D001頁。
[11] 林昇立，塑性加工學，高立圖書有限公司，1992。
[12] 黃俊明、吳運明、詹永裕，Unigraphics II模型設計基礎篇，知城數位科技股份有限公司，2002。
[13] 徐永源、丁嘉緯、王信舜，電腦輔助設計與製造(UG/CAD&CAM)，高立圖書有限公司，2005。
[14] Kunwoo Lee, Principle of CAD/CAM/CAE Systems, International Edition, Addison-Wesley, 1999, pp. 155-156.