臺灣博碩士論文加值系統

以冷間表面精抽改善圓棒與等邊型材的真直度和同心度等幾何精度時，由於精抽製程的塑性變形區Δ參數相當大，工件容易發生變形不均，造成殘留應力，影響後續產品使用之精度。
本研究首先針對圓棒在不同眼模半角、面積縮率及摩擦因子的製程參數組合下，以塑性成形有限元素法套裝軟體DEFORM-2D計算工件所需的抽引負荷，以求得具有最低成形負荷之最佳眼模半角；分析在不同眼模半角、面積縮率及摩擦因子的組合下，對位移和等效應變分佈所產生之影響，並定義「應變不均因子」以量化變形不均度。
第二部份則針對等邊型材在不同截面形狀、眼模半角、面積縮率及導圓角半徑的製程參數組合下，以DEFORM-3D計算所需成形負荷，以求得最佳眼模半角。另外分析在不同截面形狀、眼模半角、面積縮率、摩擦因子及導圓角半徑的製程參數組合下，對等效應變分佈所產生之影響，因為在角隅處等效應變較其他處顯著，故以軸心至角隅的等效應變分佈曲線作為變形不均的參考依據，以應變不均因子量化其等效應變分佈，可作為將來不同寬厚比之矩形材或不等邊型材抽引之參考依據。

Straightness and concentricity precision of round or equilateral shaped bars can be improved by cold skin-pass drawing. However the workpiece tends to deform inhomogeneously and causes residual stress with the intuitive large numbers of the delta parameter in the skin-pass process. And these factors cause bending and twist on the workpiece after subsequent heat treatment.
The current work first applies FEM software DEFORM 2D to analyze the drawing force of the skin-pass bar drawing. Optimum die semi-angles are evaluated for the process subject to a combination of various die semi-angles, reductions of area and friction factors. Distributions of displacement and effective strain are further analyzed with the same combination of process parameters. “Inhomogeneity factors in strain” are defined in order to evaluate the influences of the process parameters on deformation inhomogeneity.
The second part of the work is devoted to the analyses of skin-pass drawing of equilateral shaped bars. Optimum die semi-angles are evaluated for the process subject to a combination of various shape profiles, die semi-angles and reductions of area, with DEFORM 3D. The influence of the various process parameters on the distribution of effective strain is evaluated as well. The simulations show the corners of the shaped bars attract the most strain and hence the distribution of the effective strain across the centerline to the corner is utilized for the analyses of inhomogeneity factor in skin-pass drawing of equilateral shaped bars. The results from the round and equilateral shaped bars can serve as the guidelines for the analyses of skin-pass bar drawing of rectangular or irregular cross-sections.

摘要
Abstract
誌謝
目次
表目錄
圖目錄
第一章 緒論
1.1 前言
1.2 文獻回顧
1.3 研究目的
第二章 理論基礎與研究方法
2.1 抽引成形基本原理
2.2 圓棒表面精抽2-D模擬參數之設定
2.3 等邊型材表面精抽3-D模擬參數之設定
第三章 圓棒表面精抽模擬結果與討論
3.1成形負荷分析
3.1.1 眼模半角之影響
3.1.2 面積縮率之影響
3.1.3 摩擦因子之影響
3.2位移分析
3.2.1 眼模半角之影響
3.2.2 面積縮率之影響
3.2.3 摩擦因子之影響
3.3等效應變分析
3.3.1 眼模半角之影響
3.3.2 面積縮率之影響
3.3.3 摩擦因子之影響
3.4 應變不均分析
3.4.1 眼模半角之影響
3.4.2 面積縮率之影響
3.4.3 摩擦因子之影響
3.4.4 塑性變形參數Δ之影響
第四章 等邊型材表面精抽模擬結果與討論
4.1 成形負荷分析
4.1.1 眼模半角之影響
4.1.2 面積縮率之影響
4.1.3 圓角半徑之影響
4.2 等效應變分析
4.2.1 截面形狀之影響
4.2.2 眼模半角之影響
4.2.3 面積縮率之影響
4.2.4 摩擦因子之影響
4.2.5 圓角半徑之影響
4.3 應變不均分析
4.3.1 眼模半角之影響
4.3.2 面積縮率之影響
第五章 結論與建議
5.1 結論
5.2 建議
參考文獻
附錄A 有限元素法套裝軟體DEFORM之介紹與冷間表面精抽模擬參數之設定方法

[1] S. Kalpakjian, Manufacturing engineering and technology, 2nd ed. Addison-Wesley, 1992.
[2] T. Kuboki, M. Akiyama, Y. Neishi, K. Kuroda, Effect of final drawing with light reduction on the leveling of residual stress distribution in cold bar drawing, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, Vol 214, (2000) 1389-1400.
[3] T. Kuboki, M. Akiyama, Y. Neishi, K. Kuroda, Effect of die geometry on residual stress level present after bar drawing, Ironmaking and Steelmaking, Vol. 28 N0. 1, (2001) 65-71.
[4] T. Kuboki, H. Yoshikawa, Y. Neishi, K. Kuroda, M. Akiyama, Influence of back-tension on effect of skin pass in minimizing residual stress levels after cold drawing, Ironmaking and Steelmaking, Vol. 28 N0. 2, (2001) 117-121.
[5] M. Akiyama, T. Kuboki, Optimisation of method for reducing residual stresses after cold bar drawing, Ironmaking and Steelmaking, Vol. 29 N0. 2, (2002) 101-106.
[6] B.B. Basily, D.H. Sansome, Some theoretical considerations for the direct drawing of section rod from round bar, International Journal of Mechanical Science, 18 (1976) 201-208.
[7] C.B. Boër, W.R. Schneider, B. Eliasson, B. Avitzur, An upper bound approach for the direct drawing of square section rod from round bar, Proceedings of 20th International Machine tool design and research conference, Birmingham, 1979, pp. 149-156.
[8] H.C. Kim, Y. Choi, B.M. Kim, Three-dimensional rigid-plastic finite element analysis of non-steady shaped drawing process, International Journal of Machines Tools & Manufacture, 39 (1999) 1135-1155.
[9] Y.C. Kim, B.M. Kim, A study on the corner filling in the drawing of a rectangular rod from a round bar, International Journal of Machines Tools & Manufacture, 40 (2000) 2099-2117.
[10] K.L. Wang, V. Argyropoulos, Design and analysis of direct cold drawing of section rods through a single die, Journal of Materials Processing Technology, 166 (2005) 345-358.
[11] L. Bayoumi, Round-to square section drawing through flat idle rolls, International Journal of Mechanical Science, 41 (1999) 1323-1338.
[12] 許源泉，塑性加工學，全華科技圖書股份有限公司，民國93年。
[13] 黃新春、陳昌順、王進猷，塑性加工學，文京圖書股份有限公司，民國88年。
[14] 賴耿揚，抽線抽管塑性加工，復漢出版社，民國85年。
[15] 李榮顯，塑性加工學，三民書局，民國75年。
[16] M. L. Devenpeck, O. Richmond, Strip-drawing experiments with a sigmoidal die profile, Journal of Engineering for Industry, November（1965）425-428.
[17] Betzalel Avitzur, Handbook of Metal-forming Processes, John Wiley and Sons, New York, 1983.
[18] W.F. Hosford, R.M. Caddel, Metal forming: mechanics and metallurgy, Prentice-Hall, 1983.
[19] J. A. Schey, Tribology in Metalworking, AMERICAN SOCITY FOR METALS, 1983.
[20] E.M. Mielnik, Metal working since and engineering, McGraw-Hill, 1991.
[21] 管金談、許源泉，DEFORM鍛造模擬解析實務，國立虎尾技術學院機械製造工程系成形實驗室，民國89年。
[22] 有限元素法DEFORM鍛造成形軟體操作手冊。
[23] 蔡盛祺主編，鍛造模具設計手冊，金屬工業研究發展中心，民國87年。