產品微小化趨勢使得全球3C產品市場對微型金屬元件的需求日益增加。因此，如何製作這些微元件包括轉軸、插銷與連接器等，是業界深感興趣的研發主題。精密鍛造製程具有低成本、高生產率與品質穩定等優點，並可增強材料之機械強度，被視為一個具潛力的微元件生產技術。
本研究利用有限元素分析模擬與實驗方法探討微型轉軸凸輪鍛造成形製程之可行性，針對麻田散鐵系不銹鋼SUS420板料與純銅C1100圓形棒材與板材，經由圓柱壓縮實驗與圓環壓縮實驗分別獲得應力應變曲線與定剪摩擦因子，應用有限元素分析軟體DEFORM模擬長、寬與厚度分別為4.15、3.1與1 mm轉軸凸輪之鍛造成形，以預測材料的流動、應力與應變分佈與沖頭負載，探討微轉軸凸輪製程之可行性與胚料預形幾何對鍛造力與模穴充填之影響，最後進行模具設計與實際驗證。
研究結果顯示，有限元素分析方法能幫助預測微轉軸凸輪的鍛造成形，其模擬預測與實驗結果相接近，且微鍛造成形技術也成功地製作微轉軸凸輪。

The trend of miniaturization on many devices causes the demand for micro metal components in 3C markets worldwide. Therefore, it is widely attracted by the industry to develop the techniques for manufacturing the micro components including hinges, pins and connectors. The precision forging process not only has the advantages of low cost, high production rate and high quality, but also strengthens the mechanical properties of materials through texture evolution and work hardening. The precision forging is thus considered as a potential process for manufacturing micro metal components.
This study used the finite element analysis (FEA) and experimental approaches to investigate the possibility of applying the forging process to manufacturer micro hinge cams. Stainless steel (JIS SUS 420) sheets and copper (JIS C1100) sheets and rods were used in the micro forging process. Simple upsetting tests and ring compression tests were employed to obtain stress-strain curves and friction factors, respectively. The data was then used in an FEA software, DEFORM, to simulate the micro forging process of the cam with the dimensions of 4.15×3.1×1.0 mm and to predict the material flows, stress and strain distributions and forging loads. Based on the results, the possibility of using the micro forging for cam manufacturing was assessed, and the effects of the preforms on loads and die fillings were also discussed. The dies for the micro forming process were then designed and fabricated and experiments were finally conducted.
The results show that the FEA can be used to predict the micro forging process of the cams. The simulated result were very close to the experimental ones. The proposed approach based on the micro forging process had successfully been used to manufacture the cam.

摘 要 i
ABSTRACT ii
誌 謝 iii
目 錄 iv
表目錄 v
圖目錄 vi
一、緒論 1
1-1 前言 1
1-2 微轉軸凸輪及其轉軸機構概述 4
1-3 文獻回顧 8
1-4 研究動機與目的 12
二、基礎理論 14
2-1 鍛造概論 14
2-2 鍛造之製程設計 16
2-3鍛件之預形設計 17
2-4 微轉軸凸輪製程設計 20
2-5 有限元素法基本理論 21
2-6 DEFORM 軟體簡介 22
2-7 材料 26
2-8 圓柱壓縮 28
2-9 圓環壓縮 29
三、實驗方法 30
3-1 實驗設備 30
3-2 圓柱壓縮試驗 35
3-3 圓環壓縮試驗 39
3-4 微型轉軸凸輪有限元素分析 41
3-5 模具設計與製作 48
3-6 實驗步驟 48
3-7 實驗參數 51
四、結果與討論 52
五、結論 59
5-1 結論 59
5-2 未來展望 61
參考文獻 62

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