臺灣博碩士論文加值系統

輥軋是早期塑性加工中的一個重要的金屬成形加工過程，在進行輥軋，鈑材通過兩壓輥之間的縫隙，經由漸進的減壓過程完成了所需的減壓率。輥軋過程中潤滑油的使用，除了有冷卻的效果外，更有保護軋輥及鈑材表面的功能。我們在考慮輥軋過程中軋輥和鈑材粗糙度及潤滑油在液動潤滑時的行為，了解到太厚的潤滑油油膜將造成太低的摩擦，而使軋輥無法有效的輥軋鈑材，然而，太薄的油膜厚度將造成模具及工件直接的接觸形成了磨損、刻痕及其他的缺陷；太厚或太薄的油膜厚度會造成不理想的工件表面粗糙度，增加製程上的困擾。所以，充分的認識潤滑技術會對工業生產的品質有良好的提昇。
近年來，有限元素法數值分析被廣泛地使用於金屬加工成形的分析，而和實驗數據相比較後，其模擬分析的結果被證實了它在製程及模具的設計是相當好的分析工具，為了模擬分析的資料能更精確，它必須結合模具與工件之間真實的摩擦模式，然而，現今大部份的金屬成形加工模擬分析都是使用較為簡單的摩擦模式，如庫倫定律及摩擦因子，唯有更加真實的摩擦模式才能說明軋輥及鈑材界面間複雜的摩擦及潤滑情形。
本研究之目的，主要在建立冷軋製程中混合及邊界潤滑模式。由於表面粗糙度對潤滑油流動的影響，本研究使用了含粗糙度影響下的平均雷諾方程式，因此，本文之摩潤模式結合了平面應變冷軋成形剛塑性有限元素法及潤滑摩潤理論，藉此來分析真實摩擦。另外，經由量測軋輥前、後的工件油膜厚度和表面粗糙度，預測出油膜厚度與表面粗糙度的關係或趨勢，使往後的加工過程可預先判斷出，需要多少的軋輥速度或潤滑油黏度及減壓率等因素，才能配合出某種加工條件下的油膜厚度，使得工件達到我們想要的表面粗糙度，進而讓加工所需的成本、資源更低廉、節省，使成品品質更加完善。
加工過程中參數的變化，工件與模具之間界面的真實摩擦，有傳統的外在變數（如：界面壓力、滑動速度），亦有內在變數（如：平均油膜厚度、表面粗糙度及潤滑油性質），而其又相互影響。針對在潤滑狀況下，有限元素法結合摩潤模式所得之數值結果與相關文獻及實驗結果作一探討及比較。

In the cold rolling processes ,any of several regimes of lubricants can occur at the tooling-workpiece interface .These regimes can be characterized by the fraction of interface load that is carried by the contact of the roughness peaks or asperities. W.R.D.Wilson has described four main regimes ,thick film ,thin film ,mixed and boundary .The thick film and thin film are often combined and called the full-film regimes .Here there is considerable interaction between the asperities on the roll and billet surfaces, but there is also some hydrodynamic action of the oil. Too thick a lubricant film, like full-film regime will result in a metal surface due to insufficient constraint by the rolls, while too thin a film, like mixed and boundary regimes might allow direct metal-to-metal contact which is responsible for rolls wear, billet surface scoring and other defects. Improvements in quality and productivity in industrial metal rolling require a good understanding of mechanics of this lubrication process.
Due to the development of digital computers in the past few years ,the finite element method has been extensively used for metal forming analysis and computer-based simulations has already proven themselves as valuable tools of produce ,process and tooling design . The model combines a rigid-plasticity finite element code with a lubrication analysis. The surface roughness effect on lubricant flow is included by using a average Reynolds equation based on porous medium model and the concept of percolation theory.
The simulation of the film thickness are compared with experimental measurements of surface roughness in rolling aluminum A1100 and spcc steel billet with different lubricants ,reductions and rolling speed .The most important thing is to investigate the relationship between surface roughness and film thickness in the four regimes of lubrication .

中文摘要………………………………………………………………i
英文摘要……………………………………………………………iii
誌謝………………………………………………………………………iv
目錄……………………………………………………………………..v
圖目錄……………………………………………………………………vi
表目錄…………………………………………………………………viii
符號說明……………………………………………………………….ix
一、 緒論………………………………………………………………..1
1.1 研究目的……………………………………………………………1
1.2 文獻回顧……………………………………………………………3
1.3 本研究之構成……………………………………………………11
二、 研究方法…………………………………………………………12
2.1 混合潤滑理論分析………………………………………………13
2.1.1 入口區分析…………………………………………………13
2.1.2 工作區分析…………………………………………………14
(1) 表面峰變形與塑性流的關係………………………………16
(2) 摩擦剪應力…………………………………………………17
2.2 邊界潤滑理論分析………………………………………………18
2.3 有限元素法與冷軋潤滑摩潤模式相結合………………………18
三、 輥軋實驗…………………………………………………………29
3.1 實驗設備…………………………………………………………29
3.2 實驗前處理………………………………………………………30
3.3 實驗條件…………………………………………………………30
3.4 實驗步驟…………………………………………………………30
四、 結果與討論………………………………………………………35
4.1 與其他學者文獻比較……………………………………………35
4.2 實驗與摩潤模式的驗證…………………………………………37
4.3 實驗的結果討論…………………………………………………38
五、 結論與建議………………………………………………………79
5.1 結論……………………………………………………………79
5.2 建議……………………………………………………………80
參考文獻………………………………………………………………81
附錄A…………………………………………………………………85
簡歷……………………………………………………………………87

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