臺灣博碩士論文加值系統

隨著工業技術的發展，對於多種結構用金屬管之成品尺寸精度要求越來越嚴苛，同時，能製作出高精度與高價值之端部成形機台也逐漸受到重視與開發。相較於過往的壓延與擠製加工，管端加工之管件成形有擴管、彎曲、膨出、折疊、縮口與異形加工等多種端部成形，所以管材加工成形的研究與發展在產業界有其重要性。
本研究以有限元素分析軟體DEFORM分析管端折疊成形、擴口成形、單道成形與非對稱高擴管率成形之管件端部變形行為，藉由負載曲線、成形性等數據探討管端變形行為。單道成形之模具設計能使管端在加工成形後有多種端部成形或是管端一次成形兩種不同的形狀，藉由模具的幾何設計縮減加工道次，達成單道次成形的加工優勢。非對稱擴管成形的模具設計能使成形後的管材產生非對稱形狀，模具設計分為五道次加工，每一套模具的加工有管端擴管成形或是非對稱偏心擴管成形，最終非對稱高擴管率成形的管件形狀其擴管率在70%且軸向偏心距為6.1mm。

With the development of industrial technology, the dimensional accuracy requirements for finished metal pipes for various structures are becoming more and more stringent. At the same time, end forming machines capable of producing high precision and high value are gradually gaining attention and development. Compared with the previous calendaring and extrusion processing, the forming of pipe end processing includes various forming methods, such as pipe expansion, bending, bulging, folding, shrinking and profile processing. Therefore, research and development of pipe processing and forming are of great importance in the industry.
In this study, the researcher used the finite element analysis software DEFORM to analyze the end deformation behavior of the pipe end folded, flaring, single pass forming an asymmetric high expansion rate forming. The deformation behavior of the pipe end is discussed by data such as load curve and formability. The single-pass forming die design enables the pipe ends to be formed into two different shapes which were a variety of end shapes or one end shape. By reducing the processing procedures with the geometric design of the die, the processing advantages of single pass forming are achieved. The mold design of the asymmetric pipe expansion can make the formed pipe have an asymmetrical shape. The mold design is divided into five passes, each set of dies has a pipe end expansion or an asymmetric eccentric pipe expansion. The shape of the pipe formed by the final asymmetric high expansion rate is 70% and the axial eccentricity is 6.1 mm.

目錄
論文審定書 I
誌謝 II
摘要 III
ABSTRACT IV
圖目錄 VIII
表目錄 XIII
符號說明 XV
第一章 緒論 1
1-1 前言 1
1-2 管件端部成形技術簡介與應用 2
1-3 管件端部成形文獻回顧 6
1-3-1 管件端部擴管成形相關文獻 6
1-3-2 管件端部折疊成形相關文獻 9
1-3-3 管件端部非對稱成形相關文獻 10
1-4 研究動機與目的 12
1-5 論文架構與研究流程 13
第二章 單軸拉伸試驗之實驗結果 15
2-1 管材之單軸拉伸試驗 15
2-2 拉伸試片之規格與製作 16
2-3 拉伸試驗結果 18
2-3-1 不銹鋼 SUS 304L塑流應力計算 20
2-3-2鋁合金AL-6063塑流應力計算 23
2-3-3 DIN 2391 ST35塑流應力計算 27
第三章 管件端部成形之有限元素分析 31
3-1 有限元素分析軟體DEFORM介紹 31
3-2 管件端部折疊成形與擴管成形設計概念 32
3-2-1 折疊成形與擴管成形模具設計 32
3-2-2 基本假設及參數設定 36
3-2-3 負載與衝程曲線之關係 42
3-3 管件端部單道成形模具及製程設計 44
3-4 管件端部單道次成形模擬結果 50
3-4-1 基本假設及參數設定 50
3-4-2 成形負載曲線 58
3-4-3 成形性探討 62
第四章 實驗與解析結果討論 64
4-1 模具設計與成形性量測實驗 64
4-1-1 實驗目的 64
4-1-2 實驗設備與實驗材料 64
4-1-3 實驗參數設定 67
4-1-4 實驗步驟與流程 67
4-2 實驗結果與解析結果比較 69
4-3 加工預留量之經驗公式推導 73
4-3-1 單折體積計算 74
4-3-2 圓管體積計算 80
4-3-3 加工預留量計算 81
4-4 模具之加工預留量經驗公式推導 81
4-4-1 活動式模具成形單折形狀之預留長度公式 81
4-4-2 活動式模具成形彈頭形之預留長度公式 83
第五章 非對稱高擴管率成形分析 85
5-1 非對稱高擴管率成形模具設計 86
5-2 非對稱高擴管率成形有限元素分析 90
5-2-1 基本假設與參數設定 90
5-3 非對稱高擴管率成形負載與擴管率分析 95
第六章 結論 100
6-1 管件端部單道次成形模擬與解析結果 101
6-2 非對稱高擴管率模擬結果 101
6-3 今後研究之課題 102
參考文獻 103

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