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研究生:蘇裕翔
研究生(外文):Yu-Shiang Su
論文名稱:微齒輪鍛造預形之設計與實驗
論文名稱(外文):Forging Preform Design and Experiment of Micro Gear
指導教授:張朝誠
指導教授(外文):Chao-Cheng Chang
學位類別:碩士
校院名稱:國立高雄應用科技大學
系所名稱:模具工程系碩士班
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:2007
畢業學年度:95
語文別:中文
論文頁數:102
中文關鍵詞:微鍛造預形設計微齒輪田口方法
外文關鍵詞:Micro forgingPreform designMicro gearTaguchi method
相關次數:
  • 被引用被引用:21
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  • 下載下載:237
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本研究利用數值模擬與田口方法設計微齒輪之鍛造預形,並製作模具以進行實驗驗證。鍛造預形設計以胚料與模具之幾何特徵為設計變數,包括胚料體積、胚料直徑、預形模具之圓角等,藉由數值模擬並搭配田口方法,以兩個階段之常溫微鍛造成形為製程,針對模數為0.15、具有28與14齒、厚度各為0.5 mm之雙層齒輪,且兩端各有2 mm直徑轉軸之微齒輪元件,以可完全充填齒輪模穴與最小鍛造能量為目標,設計一組微鍛造預形模具。微齒輪材料為純銅C1100,而模擬所需之應力應變曲線則經由壓縮試驗獲得。研究結果顯示,數值模擬與田口方法能幫助微齒輪的鍛造預形設計,而微齒輪元件中之大齒輪可經微鍛造成功地成形,但其小齒輪則無法完全成形,材料充填模穴之模擬預測與實驗接近。微鍛造是具有潛力的金屬微齒輪成形技術。
The study uses a numerical simulation technique and the Taguchi method to design preforms for the micro forging of a gear. The predicted profiles of the dies were then used to construct a set of dies for the experiments. In this study, the geometric features of the billet and the die are main design variables for the preform of the micro forged gear. The variables include the volume and diameter of the billet, and the radii of the preform dies. By a two-stage micro forging process consist of the perform stage and the finished stage, a micro gear component having two gears of 28 and 14 teeth with the module of 0.15 and the thickness of 0.5 mm is micro-forged at the room temperature. The gear component also has two shafts with the diameter of 2 mm on both ends. The design target of the preform is to fulfill the complete filling of the die cavities in the finish stage of the micro forging and to minimize the energy required in entire micro forging process. The gear material is copper (C1100) and the required stress-strain curves are obtained from simple up-setting experiments. The designed preforms were then used to fabricate the dies for the experiments of the micro forging of gears. The results show that the predicted metal flows during the micro forging process are similar to those in experiments. The numerical simulation and the Taguchi method can help the design of the preforms for the micro forging gear. The 28-teeth gear can be produced by a two-stage micro forging process, but further study on the complete die filling of 14-teeth gear is still needed. The micro forging process is a potential technique for the manufacturing of metallic micro gears.
目錄
摘 要 i
ABSTRACT ii
表目錄 vi
圖目錄 vii
一、緒論 1
1-1 前言 1
1-2文獻回顧 2
1-3 研究動機與目的 8
二、鍛造基本理論 10
2-1 鍛造概論 10
2-2鍛造之製程設計 11
2-3鍛件之成形設計 13
2-4鍛件之預形設計 15
三、田口式實驗法 20
3-1田口品質工程理論 20
3-1-1 品質損失函數 20
3-1-2 參數設計 21
3-1-3 直交表設計 21
3-1-4 信號雜音比之特性 22
3-1-5 變異數分析(Analysis of Variance ) 23
3-2 微鍛造成形參數設定 24
3-2-1 確認品質特性 24
3-2-2 決定控制因子 25
3-2-3 直交表實驗設計 25
四、DEFORM模擬與材料實驗 30
4-1有限元素法基本理論 30
4-2 DEFORM軟體簡介 31
4-3材料機械性質 33
4-3-1 材料 34
4-3-2 實驗設備 34
4-3-3圓柱壓縮試驗 35
4-4微齒輪設計 38
4-5 DEFORM模擬 41
五、實驗設備與方法 43
5-1 模具設計與製作 43
5-2 實驗步驟 44
5-3 實驗參數 48
六、結果與討論 49
6-1直交表實驗結果分析 49
6-2 模擬結果分析 51
6-3 實驗驗證 57
七、結論與未來展望 77
7-1結論 77
7-2 未來展望 78
參考文獻 79
附錄:微齒輪鍛造模具圖 82
簡歷 91
參考文獻
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