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 鍛造成品件的形狀有愈來愈複雜的趨勢，本文主要以實際工業界的案例利用有限元素法作分析並加以改善，並配合實際成品件作驗證。 對於二維的案例中，主要以啦叭鐵心件作為分析模型，針對在實際生產過程會有疊料的現象，歸納出可能影響疊料情形的參數加以分析設計，並將改善後的結果加以驗證，確定有限元素法模擬分析的可靠性。 三維鍛造模擬技術至今並不是很成熟，在模擬過程中所發生的問題，主要以元素的大小及個數最難控制，需選出最適當的網格分佈，以及模擬時間過長的問題。
 In general, the shapes of most forging products are complicated. A simplified FEM model, such as axisymmetric model and plane-strain model, can not simulate completely forming processes of forging. Therefore, a three-dimensional FEM model is necessary to describe the geometric configuration of forging product and to simulate forming processes of those. For axisymmetric objects, a forming process of axisymmetric object simulated by FEM in this study is used to analyze defects of forging process of that. The major defects investigated by this study are folding and fracture. The improvements for the defects are verified by results of FEM analysis to obtain guideline for designing die and perform geometry. For complicated shape of forging product, a three-dimensional FEM, DEFORM 3D, is adopted to simulate the forming process of those. However, in the three-dimensional FEM, element size and mesh density are contributing factors to simulated analysis of FEM. Therefore, the proper element size and the excellent mesh density are determined by this study to simulate forging processes and to obtain more accuracy results.
 第一章 緒論 1.1 前言…………………………………………………………..1-1 1.2 研究動機與目的…………………………………………..…1-2 1.3 研究方法與軟體的使用……………………………..………1-3 1.4 文獻回顧………………………………………………….….1-9 1.5 論文總覽……………………………………………………..1-9 第二章 材料機械性質實驗 2.1 前言…………………………………………………..……….2-1 2.2 圓柱壓縮實驗……………………………………………...…2-2 2.1.1 實驗機器與實驗步驟……………………………..….2-2 2.1.2 應力-應變曲線校正………………………….………2-5 2.2 圓環壓縮實驗……………………………………………….2-9 2.2.1 試片潤滑處理………………………………………….2-9 2.2.2 以電腦模擬建立摩擦校正曲線………………...……2-12 2.3 定義破壞常數………………………………………...……2-13 2.3.1 破壞準則…………………………………………...…2-13 2.3.2 求取破壞常數之實驗……………………………...…2-14 2.3.3 實際破壞件與有限元素法模擬比對……………...…2-15 第三章 影響鐵心預成形之設計參數分析 3.1 前言………………………………..…………………………3-1 3.2 製程參數之模擬分析…………….………………………….3-5 3.2.1 摩擦效應的影響…………….………………………3-7 3.2.2 鍛胚階梯面與模面之間隙…………...………..……3-9 3.2.3 鍛胚與下部沖頭之間隙………...…………………3-12 3.2.4 結果討論………………………...…………………3-13 3.3 應用於實際成品（1）………………..……………………3-15 3.3.1 物件1-疊料分析與改善…………………………3-15 3.1.2 缺陷的產生與成因……………...…………………3-17 3.3.3 製程參數與模擬步驟……………...………………3-18 3.3.4 模擬結果討論…………………..…….……………3-19 3.4 應用於實際成品（2）……………..….………….…………3-25 3.4.1 物件2-疊料分析與改善…………….……………3-25 3.4.2 製程參數與模擬步驟………………...……………3-26 3.4.3 改變鍛胚形狀……………………...………………3-27 3.4.4 模擬結果討論…………………...…………………3-31 3.5 應用於實際成品（3）…………………..…………………3-37 3.1.1 物件3-疊料分析與改善…………………………3-37 3.5.2 製程參數與模擬步驟…………...…………………3-38 3.5.3 鍛胚與模面及下部沖頭之間隙………...…………3-39 第四章 三維有限元素法模擬之應用與驗證 4.1 前言………………………………………………………..…4-1 4.2 探討模擬汽車前輪軸連結器之網格體積流失..................…4-3 4.2.1 簡單壓縮之網格體積流失問題…...………………4-3 4.2.2 汽車前輪軸連結器之應用……………………...……4-8 4.3 三維鍛造模擬應用與驗證…………………………………4-14 4.3.1 利用二維簡易模式判斷其材料流動型式…….....…4-18 4.3.2 簡化有限元素法模擬之鍛件形狀……………….…4-21 4.3.3 探討影響具有內孔齒形之轉子的成形因素…….…4-26 第五章 結論…………………………………………………………5-1 參考文獻
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 1 MARC應用於冷鍛加工分析及其驗證 2 熱鍛模具設計之有限元素法分析 3 鉚接扣件多道次之冷鍛製程分析 4 鋁基金屬複合材料活塞鍛造成形特性分析與模具設計 5 漸開線外齒輪鍛造之有限元素法 6 LED六角錐散熱片設計分析與模具開發 7 軸向對稱閉模鍛造之有限元素分析

 1 [20] 林君明, 林鴻志, ”全球定位系統及信號處理法則研究”,中國航空太空學會學刊, 第二十八卷第二期, 1996, pp153-161

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