# 臺灣博碩士論文加值系統

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 矩形材是線性滑軌或滑塊之類零件輪廓的簡化形狀，但是矩形材也較等邊形材抽製複雜，必須考慮矩形材寬度與厚度的合理縮率組合，及採用不同眼模半角的組合條件下，以獲得矩形材最低抽製應力與最佳成形均勻度的眼模設計規範。 本文首先藉由有限元素法套裝軟體DEFORM-3D模擬矩形材抽製，探討不同眼模半角與面積縮率對抽製應力的影響，並以多餘變形因子來估算工件的變形不均勻度；再進一步驗證矩形材抽製成形的眼模設計法則，針對不同寬厚比之矩形材，以不同縮率組合，進行不同眼模半角組合之最佳眼模半角選用範圍之預測，另外也評估在不同寬度與厚度縮率組合所造成變形不均勻程度的影響。結果顯示，部份縮率組合最佳眼模半角值均在法則預測範圍區間內；部份案例超出範圍但偏差值仍屬少量。矩形材抽製之最佳眼模半角所對應之多餘變形因子區間，皆落在預測範圍內。 第二部份則針對10%與15%二種面積縮率為例，寬度與厚度方向使用相同眼模半角的條件下，寬度與厚度縮率組合對於抽製應力與工件多餘變形的影響，尋求是否存在最佳縮率組合，使得抽製應力為最低，或者得到最佳成形均勻度。結果顯示，在寬度方向施加較少的縮減率，或是在厚度方向施加較多的縮減率時，整體的抽製應力會下降。當寬度與厚度縮率組合之比，等於其寬厚比之反比時，可得到最低的多餘變形因子，亦即最佳的變形均勻度。
 Rectangular shapes are the simplified geometries of linear rails or sliders. But the theory behind drawing with rectangular shapes is more complicated with drawing with shapes of equal-lateral sides. In order to obtain minimum drawing stress or homogeneity, additional parameters such as reasonable combinations of width and thickness reductions as well as die semi-angles along the two directions have to be considered.This work starts with evaluating the influence of die semi-angle and reduction of area on drawing stress with the aid of FEM software DEFORM-3D. Redundant deformation factor was utilized to estimate workpiece’s deformation inhomogeneity. The data base was further used to verify the guideline in selecting optimum die semi-angles in drawing rectangular shapes with unequal width and thickness reductions. The corresponding redundant deformation factor was also evaluated. The results showed that some cases had good agreement with the guideline while some results fell out of the predicted range. However the error was minimal. The corresponding redundant deformation factors were well predicted with the guideline.The second part focuses on drawing with 10 and 15% reductions of area. The optimum combination of width and thickness reductions was evaluated under the condition of drawing with same die semi-angle in the width and thickness directions. The results showed that drawing stress could be reduced with less reduction in the width direction. The minimum redundant deformation factor could be obtained when the ratio of width to thickness reduction equal to the inverse of the shape’s width-to-thickness ratio.
 摘要......................................................iABSTRACT.................................................ii誌謝....................................................iii目錄.....................................................iv表目錄...................................................vi圖目錄..................................................vii第一章 緒論...............................................11.1 前言..................................................11.2 文獻回顧..............................................21.3 研究目的..............................................51.4 論文總覽..............................................6第二章 理論基礎與研究方法.................................72.1 抽製成形基本原理......................................72.2 金屬成形之分析理論....................................92.3 矩形材抽製模擬參數設定...............................122.4 不同寬與厚縮率矩形材抽製之最佳眼模半角選用法則.......16第三章 矩形材抽製之最佳眼模半角選用法則之驗證............193.1寬度與厚度方向使用相同眼模半角及縮率之抽製............213.1.1 最佳眼模半角.......................................213.1.2 多餘變形因子.......................................233.2 不同寬度與厚度縮率矩形材之眼模半角選用法則驗證.......253.2.1 寬度-厚度縮率為2.5%-7.5%...........................253.2.2 寬度-厚度縮率為7.5%-2.5%...........................313.2.3 寬度-厚度縮率為5%-10%..............................373.2.4 寬度-厚度縮率為10%-5%..............................433.2.5 不同寬厚比對眼模半角選用與驗證之比較...............50第四章 寬度與厚度縮率對矩形材抽製之影響..................534.1 抽製應力分析.........................................534.2 多餘變形因子分析.....................................554.2.1 面積縮率10%........................................554.2.2 面積縮率15%........................................574.3 應變分佈分析.........................................59第五章 結論與建議........................................635.1 結論.................................................635.2 建議.................................................65參考文獻.................................................66英文論文大綱.............................................68
 [1]W. Steuff, R. Kopp, “Estimation of designing methods for drawing of section rods and wire”, Wire J. International, Vol. 28, No. 3 (1995), 104-109.[2]M. Kobayashi, “The present situation of cold drawn special sections, Journal of the JSTP”, Vol. 39, N0. 447 (1998) 335-337.[3]H.S. Lin, Y.C. Hsu, C.C. Keh, “Inhomogeneous deformation and residual stress in skin-pass axisymmetric drawing”, Journal of Materials Processing Technology 201 (2008) 128-132.[4]曾竹毅，矩形材淺抽成形之眼模半角選定與其變形不均分析，國立虎尾科技大學碩士論文，民國97年。[5]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.[6]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.[7]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.[8]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 Machine Tools & Manufacture, 40 (2000) 2099-2117.[9]M. Kobayashi, “The present situation of cold drawn special sections”, Journal of the JSTP, Vol. 39, N0. 447 (1998) 335-337.[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]范光堯，生醫用鈦合金異形材抽拉製程的開發，國科會專題研究計畫成果報告，計畫編號：NSC92-2622-E-005-008-CC3。[13]許源泉，塑性加工學，全華科技圖書股份有限公司，民國94年。[14]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。[15]賴耿揚，抽線抽管塑性加工，復漢出版社，民國85年。[16]李榮顯，塑性加工學，三民書局，民國75年。[17]W. F. Hosford and R. M. Caddell, “Metal Forming, Mechanics and Metallurgy” , Prentice Hall, 1983.[18]M. L. Devenpeck, O. Richmond, “Strip-drawing experiments with a sigmoidal die profile,” Journal of Engineering for Industry, November (1965) 425 - 428.[19]Mohsen Kazeminezhad, “A study on the computation of the redundant deformation factor in wire drawing of austenitic 304 stainless steel”, Journal of Materials Processing Technology, 2008, 230-233.
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 1 矩形材淺抽成形之眼模半角選定與其變形不均分析 2 定剪摩擦下以模具旋轉抽製線材成形參數最佳化研究

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 1 自行車橢圓管精抽製程分析與改善 2 鋁管抽製最佳化設計之有限單元分析 3 矩形材淺抽成形之眼模半角選定與其變形不均分析 4 非軸對稱擠製與抽製加工之研究 5 金屬圓棒無模具錐釘抽製成形研究 6 冷間精抽不均勻變形之CAE分析 7 金屬圓棒抽線製程設計與分析暨三探針式檢測系統之開發 8 棒材與板材表面精抽之不均勻變形與殘留應力分析 9 金屬線材多道次伸線過程中鑽石眼模之尺寸設計及磨耗分析 10 特殊合金抽線眼模之最佳化設計 11 多道次冷抽鋼管成形製程與模具設計 12 鎂合金橢圓杯深引伸過程板材外型之預測 13 鎂合金數位相機外殼衝壓成形之多道次製程設計與分析 14 自行車座管擠製製程之有限元素分析 15 不銹鋼線材伸線製程之參數研究

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