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研究生:林彥儒
研究生(外文):Yan-Ru Lin
論文名稱:六角頭剪模設計與分析
論文名稱(外文):A study on the design and analysis of the hexagonal hole within the trim die
指導教授:許昭和許昭和引用關係
指導教授(外文):Chao-Ho Hsu
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
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:2009
畢業學年度:97
語文別:中文
論文頁數:81
中文關鍵詞:延性破壞準則。六角剪模直交表準確性頂出棒係數值剪斷面田口方法
外文關鍵詞:Trim dieTaguchi methodANDFracture criteria
相關次數:
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  • 下載下載:23
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本研究應用金屬成形分析搭配正規化的Cockcroft and Latham 延性破壞理論,來分析頭部對角為38mm的六角螺栓之六角頭剪斷過程。本文使用DEFORM™-3D作金屬成形分析,並以田口式直交表(Taguchi’s orthogonal array)對所選定之製程條件做適當之水準規劃,以獲得最佳之參數組合,達到目標尺寸且產生最少廢料。所探討的有六角剪模之入刀口圓角半徑值與速度、胚料之破壞係數值、及各個工具與胚料之摩擦係數等。

本研究使用PRO-E設計出剪斷時所使用的六角剪模、下模與頂出棒,爾後轉成*.stl檔匯入DEFORM™-3D進行前處理設定及模擬分析胚料之剪斷過程。由於產品的對稱性,故將其胚料分成1/12進行分析,可節省分析的時間與增加分析的準確性。

研究結果顯示:經適當地調整六角剪模之入刀口圓角半徑,模擬會趨近目標尺寸,且毛邊高度會越小。而胚料之抗拉強度與破壞係數值為影響衝剪斷面之品質的主要因素。經田口方法的分析所得到的最佳參數,可使產品的尺寸精度提升0.11%,而廢料體積減少4.59%。研究結果可提供製程與設計相關人員,在開發新產品時作為參考。
The study uses the metal forming simulation and normalized Cockcroft and Latham fracture theory to analyze the shearing process on the head to 38mm diagonal of the hexagon bolt. In this paper, we use software package DEFORM™-3D and the selected process conditions appropriate level of planning were determined by using Taguchi’s orthogonal array, to obtain the best parameter combination, to achieve the target size and a minimum of waste generated. The considered are the corner radius and the velocity of the trim die, damage value of the workpiece and the friction coefficient between the tools and the workpiece.
The analysis consisted of creating trim die, bottom die and knockout pin geometries using Pro/engineering during the trimming process, whereupon importing them into the finite-element analysis (FEA) package DEFORM™-3D to set up simulation in the pre-process. Since the product is symmetrical, therefore the material will be divided into 1/12. It not only decreases the analyzing time but also increases the precision of the simulation.
The result show: by the appropriate adjustments to the value of corner radius, simulation will be closer to the target size and the burr height will be smaller. The tensile strength and damage values of the material are the main factors affect the punching. The optimum parameters we obtained by Taguchi method, can make the dimension precision of product step up to 0.11%, but the waste generated of product decrease to 4.59%. From this results it can provide some references to personnel who is process and design in the development of new products.
中文摘要 ………………………………………………………………… i
Abstract ………………………………………………………………… ii
誌謝 ………………………………………………………………… iii
目錄 ………………………………………………………………… iv
表目錄 ………………………………………………………………… vi
圖目錄 ………………………………………………………………… vii
第一章 緒論 …..……………………………………………………… 1
1.1 前言 ..………………………………………………………… 1
1.2 文獻回顧 ….…………………………………………………. 1
1.3 研究動機與目的 ….…………………………………………. 5
第二章 基本理論 …..………………………………………………… 6
2.1 冷作成形概論 ....…………………………………………….. 6
2.1.1 冷作之基礎 .............................................................................. 6
2.1.2 冷作加工之分類 ...................................................................... 7
2.1.3 衝剪加工(shearing)............................................................... 8
2.2 衝剪基本理論 .......................................................................... 8
2.2.1 衝剪過程 .................................................................................. 8
2.2.2 衝剪斷面 .................................................................................. 9
2.2.3 基本衝剪應力理論 .................................................................. 9
2.3 延性破壞準則之比較探討 ...................................................... 9
2.4 臨界之破壞值 .......................................................................... 12
2.5 基本假設 .................................................................................. 13
2.6 材料屬性 ….............................................................................. 13
2.7 DEFORM-3D 使用之摩擦定律 …......................................... 14
2.8 有限元素法於塑性加工上之應用…........................................ 15
2.8.1 切片法(Slab method)…........................................................ 15
2.8.2 均勻變形能量法(Uniform deformation energy method)… 15
2.8.3 滑移線場法(Slip line field method)…................................. 15
2.8.4 極限解析法(Linit analysis)….............................................. 15
2.8.4.1 上界限法(Upper bound method) ….................................... 15
2.8.4.2 下界限法(Lower bound method) …................................... 16
2.8.5 有限元素法 …......................................................................... 16
第三章 田口方法與衝剪實驗參數規劃…............................................ 20
3.1 田口品質工程基本理論…........................................................ 20
3.1.1 品質損失函數…........................................................................ 20
3.1.2 直交表….................................................................................... 21
3.1.3 信號雜音比(S/N比)….................................................. 21
3.2 衝剪實驗參數規劃並定義設計參數….......................... 23
3.2.1 直交表實驗設計….................................................................... 23
3.2.2 決定目標特性…........................................................................ 23
3.2.3 模擬參數設計…........................................................................ 23
3.2.4 六角頭剪模…............................................................................ 24
第四章 DEFORM™-3D模擬分析軟體簡介….................................... 26
4.1 DEFORM金屬成形分析軟體介紹…...................................... 26
4.1.1 DEFORM-3D之優點與特色介紹…........................................ 27
4.1.2 前處理(Pre-processor)…...................................................... 29
4.1.3 模擬引擎(Simulation Engine)….......................................... 30
4.1.4 後處理(Post-processor)…..................................................... 30
4.2 DEFORM-3D衝剪成形製程設定…........................................ 30
第五章 製程分析與改善….................................................................... 32
5.1 螺栓製程簡介…........................................................................ 32
5.2 六角頭剪模簡介….................................................................... 32
5.3 DEFORM模擬條件設定…...................................................... 34
5.4 DEFORM 模擬分析結果…..................................................... 41
第六章 結果與討論…........................................................................... 46
6.1 田口法實驗模擬分析…............................................................ 46
6.2 衝剪斷面…................................................................................ 47
6.3 成形對角尺寸…........................................................................ 52
6.4 剪斷廢料體積…........................................................................ 54
6.5 比較最佳化之模具參數與原始參數….................................... 56
6.6 比較模擬結果與實際試打….................................................... 57
第七章 結論與建議…............................................................................ 59
7.1 結論…........................................................................................ 59
7.2 建議…........................................................................................ 59
參考文獻 …................................................................................................ 60
作者簡介 …................................................................................................ 62
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