臺灣博碩士論文加值系統

近年來電腦處理器之速度越來越快因而產生的大量的熱，如何將熱量藉由散熱媒介快速有效地排除是值得研究的問題。為求有效增加散熱面積並大幅提昇散熱效率，鍛造製程為唯一可行的方法。本研究先就散熱片鋁合金前向擠出製程中的成形參數，以DEFORM模擬軟體進行分析，並以最佳之參數做為模具設計的依據。再使用A6061鋁合金為胚料進行實際鍛造實驗，進行驗證。
結果顯示，根據DEFORM模擬得知成形圓角半徑與成形負荷呈現正比的趨勢，而鰭片直度與成形部長度亦成正比。在本實驗中 ，圓角半徑為0.5mm，成形部長度為5mm為其最佳成形參數，為成形負荷最小22噸且鰭片直度最佳。使用此最佳參數進行擠製模具設計。鍛造實驗所得之成形負荷與鍛件外觀皆與DEFORM模擬結果相當吻合。因此藉由DEFORM模擬分析最佳成形參數，作為散熱片前向擠出模具設計的依據是可行的。

Recently, the speed of the computer processor is getting faster and faster, which is followed by generation of a great deal of heat. How to eliminate the heat fast and effectively by using the heat conductive media is a topic worth to research. The efficiency of the heat sink depends on material properties and the effective heat surface area for conduction. Forging is the only process to increase the surface area of a heat sink to promote the efficiency of heat conductivity. In this study, the forward extrusion process variables of a heat sink of aluminum are investigated. First the CAE software, “DEFORM-3D”, is used to analyze the forward extrusion process and the variables in extrusion die design are investigated. Then, the optimum variables according to the results of CAE simulation are used to design the actual die and are certified by the forging experiment using A6061 aluminum alloy as the billet.
The results show that the forging loads are proportional to radii of die. When the land is 5mm, the fins of heat sink are the straightest. The load of 22 tons is the lowest and the fins are straightest when the radius is 0.5mm and the land is 5mm, which are the optimum variable in the CAE simulation. Then the optimum conditions are used to design the extrusion dies and proceed with the forging experiment. Not only the forging load but also the stress distribution and product appearance in the actual forging conform to those in the DEFORM simulation. Therefore, it is feasible that using the DEFORM software simulates the forging process to find the optimum variables previously and then the design of the forging die is proceeded according to the optimum variables.

中文摘要 ……………………………………………………………………………Ⅰ
英文摘要 ……………………………………………………………………………Ⅱ
目錄………………………………………………………………………………… Ⅳ
圖目錄 ………………………………………………………………………………Ⅶ
表目錄 …………………………………………………………………………… ⅩⅡ
第一章 緒論 ………………………………………………………………………1
1-1.前言………………………………………………………………………………1
1-1-1.散熱片熱傳導模式 ………………………………………………………4
1-1-2.鍛造製程………………………………………………………………… 6
1-1-2-1.冷鍛之特色……………………………………………………… 7
1-1-2-2.冷鍛潤滑………………………………………………………… 8
1-1-2-3.前向擠出鍛造…………………………………………………… 9
1-1-3.鋁合金之冷鍛製程………………………………………………………12
1-1-3-1.鋁合金材料的分類 …………………………………………… 12
1-1-3-2.鋁合金鍛造用素材之種類 …………………………………… 14
1-1-3-3.鋁合金退火處理 ……………………………………………… 14
1-1-3-4.鋁合金潤滑處理 ……………………………………………… 17
1-1-4.CAE有限元素分析法在鍛造上之應用………………………………… 20
1-1-4-1.電腦輔助工程技術於鍛造工業之應用……………………… 20
1-1-4-2.DEFORM模擬軟體簡介 ………………………………………… 21
1-2.研究目的……………………………………………………………………… 22
1-3.文獻回顧……………………………………………………………………… 24
第二章 實驗方法 …………………………………………………………………26
2-1.實驗架構與流程 ……………………………………………………………26
2-2.目標載具設計 ……………………………………………………………… 27
2-3.DEFORM模擬規劃 ………………………………………………………… 29
2-3-1環境參數設定 ………………………………………………………… 30
2-3-2.成形部參數設定 ……………………………………………………… 31
2-3-3.數值模擬配置 ………………………………………………………… 31
2-3-4.模具應力分析模擬 …………………………………………………… 35
2-4.鍛造實驗設備…………………………………………………………………37
2-5.模具設計……………………………………………………………………… 42
第三章 結果與討論……………………………………………………………… 64
3-1. CAE成形模擬…………………………………………………………………64
3-1-1.成形部參數對成形負荷之影響………………………………………… 64
3-1-1-1.成形部長度對於成形負荷之影響 ………………………… 64
3-1-1-2.成形部圓角半徑對於成形負荷之影響……………………… 68
3-1-2.成形部參數對鰭片偏移之影響………………………………………… 72
3-1-2-1.成形矯正部對於鰭片偏移之影響…………………………… 75
3-1-2-2.成形圓角半徑對於鰭片偏移之影響………………………… 76
3-1-3.鰭片數密度對成形負荷之影響 ……………………………………… 77
3-2.CAE模具應力分析………………………………………………………… 78
3-2-1.上模仁應力分析 ……………………………………………………… 78
3-2-2.下模仁應力分析 ……………………………………………………… 81
3-3. 實體散熱片鍛造模具設計……………………………………………… 83
3-3-1.成形部參數設計 ……………………………………………………… 83
3-3-2.成形部模具設計 ……………………………………………………… 84
3-4.鍛造實驗與分析…………………………………………………………… 89
3-4-1.鍛造實驗結果探討 …………………………………………………… 89
3-4-2.鍛造實驗之鍛件外觀與DEFORM模擬結果比較…………………………91
第四章 結論與建議 …………………………………………………………… 97
4-1.結論 ……………………………………………………………………… 97
4-2.建議 ……………………………………………………………………… 98
參考文獻 ……………………………………………………………………………99
附錄A.單鰭片模擬資料……………………………………………………… 101

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