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研究生:楊仁智
研究生(外文):Ren-Chih Yang
論文名稱:方筒深引伸成形之製程分析與模具設計之研究
論文名稱(外文):A Study of Deep Drawing Process and Die Design of The Square Cup
指導教授:楊俊彬楊俊彬引用關係
指導教授(外文):Jin-bin Yang
學位類別:碩士
校院名稱:國立高雄第一科技大學
系所名稱:機械與自動化工程所
學門:工程學門
學類:機械工程學類
論文種類:學術論文
論文出版年:2002
畢業學年度:90
語文別:中文
論文頁數:123
中文關鍵詞:手機型鋰電池外殼深引伸
外文關鍵詞:mobile-phone battery shelldeep drawing
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摘要
國內之引伸技術仍停留在淺引伸技術上,對於困難度較高的深引伸成形技術仍有些缺點﹐深引伸模具更是無法自行設計開發。深引伸加工技術由於涉及材料特性,製程中不易控制材料之流動性,因此需要高層次之模具設計與製程技術。而深引伸成形中又以方形筒件之引伸層次最高,究其原因,製程參數尚未建立,材料流動較為複雜。而方筒引伸件目前使用最多為電池外殼,所以本次研究將以手機型鋰電池外殼做方筒深引伸技術之探討,利用有限元素分析軟體”DEFORM”分析下得到最少引伸道次數量、最佳引伸形狀和引伸模具形式等,利用分析所得之結果設計開發深引伸模具,經由實際引伸探討深引伸過程中無法由CAE分析得到之過程,再以實際引伸得到之引伸件比較分析所得之結果,探討利用CAE分析多道次深引伸製程之可行性。
結果顯示,經由CAE分析,可以在第一道次中得到對於鋁合金直徑60mm橢圓引伸範圍,並從中可以得知橢圓引伸件長軸40mm、短軸26mm其引伸長度最長,引伸杯口最平整且引伸厚度變化小。在第二道次中可以分析得兩組方形尺寸,方形長邊32mm,短邊10mm其引伸長度最長,方形長邊35mm、短邊12mm引伸長度略短但是引伸件杯口平整。第三道次以此兩組方形尺寸引伸分析得到方形長邊32mm、短邊10mm可直接引伸得到完成件,而方形長邊35mm、短邊12mm無法直接引伸得到完成件,需再一道次引伸即可引伸得到完成件。以上述道次進行實際引伸。引伸實驗發現在第一道次所得之引伸件引伸長度比CAE分析所得之引伸件短,但在厚度也未因引伸產生變薄現象。第二道次上所得之引伸件也較短,但在厚度上也未因引伸而變薄,在引伸件表面上會因為退火製程之關係產生橘皮狀。第三道次引伸試驗會因為產生皺折導致引伸破裂,添加壓料元件雖可以減少皺折產生,但是仍會引伸破裂,需要壓料元件與沖頭同動,使得引伸成形過程中壓料件能一直壓住胚料避免產生皺折。
Square cup deep drawing process is a key point of drawing technology. However the drawing technology gradation of Taiwan is still staying in shallow drawing, and not yet develops square cup deep drawing die design technology. Involving with material properties, it is not easy to control the material flow in deep drawing process. By the condition, we need high-level die design for deep drawing process. The square cup deep drawing process is the highest level of deep drawing technologies. The reason is the complex material flow and the parameters of square cup deep drawing process are not established. The application of square cup deep drawing process is popularly used in manufacturing all kinds of battery shells. In this study, the mobile-phone battery shell square cup deep drawing technology will be investigated. By using FEM software “DEFORM” to analyze the variables, including the drawing steps, the condition of the material surface, and the drawing die design etc. Using. The simulation optimum results to design the drawing die and then carry out the experiment. Finally the feasibility is discussed by confirming with the simulation data and the experiment result.
By the aluminum billet diameter is 60mm, the deepest drawing distance, smooth surface condition, and the less variation of thickness can be obtained during the variables of the first oval-shaped drawing step are major axis 40mm and minor axis 26mm. During the second step of square drawing, we can get two square shape conditions, the condition of major edge 32mm, minor edge 10 mm get the most high drawing length, another condition of major edge 35mm, minor edge 10mm has best square cup shape. At the third step of square shape drawing, the condition of major edge 32mm, minor edge 10mm is success to obtain the expected product, and the other condition of major edge 35mm. Minor edge 12mm is failure, need one more stamp to get the expected product. Through the reality-drawing test, we can find that reality drawing length more long than analysis’s length, and reality drawing thickness does not become thin. In second stamp, reality-drawing’s length is shorter than analysis’s drawing, and the thickness dose not become thin during drawing. In the drawing surface will obtain the coarse skin by the annealing process. In the third stamp drawing test, the drawing will crack by occurring wrinkle, add the holding element still will crack, it needs holding element and punch movement at the same time to take the holding element always pressing the drawing by the drawing process.
目錄
中文摘要 ………………………………………………………………………Ⅰ
英文摘要 ………………………………………………………………………Ⅲ
目錄 ……………………………………………………………………………Ⅴ
圖目錄 …………………………………………………………………………Ⅷ
表目錄 …………………………………………………………………………ⅩⅣ
第一章 緒論 …………………………………………………………………1
1-1 研究背景…………………………………………………………1
1-1-1 深引伸模具市場分析………………………………………2
1-1-2 深引伸模具技術現況………………………………………4
1-1-3 與先進國家技術差距及國內技術瓶頸……………………6
1-1-4 技術發展動向………………………………………………8
1-2 文獻回顧…………………………………………………………12
1-3 研究動機與目的…………………………………………………14
第二章 研究方法 ……………………………………………………………15
2-1 CAE分析之基本假設 …………………………………………16
2-2 實驗材料 ………………………………………………………17
2-3 下料尺寸設計 …………………………………………………18
2-4現有實驗設備……………………………………………………19
2-4-1成形機台 ……………………………………………………19
2-4-2 共用模組 ……………………………………………………21
2-5 CAE分析製程規劃 …………………………………………………22
2-5-1第一道次引伸模擬分析規劃…………………………………22
2-5-2第二道次引伸模擬分析規劃…………………………………26
2-5-3第三道次引伸模擬分析規劃…………………………………30
2-6方筒殼件深引伸模具設計 …………………………………………34
2-6-1第一道次模具設計 ……………………………………………34
2-6-2第二道次模具設計 ……………………………………………41
2-6-3第三道次模具設計 ……………………………………………46
2-6-4模具材料選用 …………………………………………………46
2-7模具精修與組裝 ……………………………………………………51
第三章結果與討論 ……………………………………………………………64
3-1 CAE成形分析討論 …………………………………………………64
3-1-1 第一道次成形分析 ……………………………………………64
3-1-2 第二道次成形分析 ……………………………………………70
3-1-3 第三道次成形分析 ……………………………………………79
3-1-4 第四道次成形分析 ……………………………………………80
3-1-5 成形道次討論 …………………………………………………86
3-2實際引伸試驗 ………………………………………………………89
3-2-1 第一道次實際引伸作業 ………………………………………89
3-2-1-1 引伸成形試驗 ……………………………………………89
3-2-1-2 成形缺陷與改善 …………………………………………91
3-2-1-3 實際引伸試驗與CAE模擬引伸試驗之比較 ……………97
3-2-2 第二道次實際引伸作業 ……………………………………102
3-2-2-1引伸成形試驗 ……………………………………………102
3-2-2-2成形缺陷與改善 …………………………………………104
3-2-2-3實際引伸試驗與CAE模擬引伸試驗之比較 ……………109
3-2-3第三道次實際引伸作業 ………………………………………112
3-2-3-1引伸成形試驗 ……………………………………………112
3-2-3-2成形缺陷與改善 …………………………………………114
第四章結論……………………………………………………………………120
第五章參考文獻………………………………………………………………122
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