連續輥軋是以一序列的輥輪將平板狀鈑金輥軋成複雜斷面形狀，其產品主要應用在建築業(如結構件及天花板裝潢用輕鋼架)、航空業(如飛機隔框)、汽車業(窗框) 、腳踏車(輪框) 及石油業(大型ERW圓管)。連續輥軋產品之模具設計開發，目前仍依賴經驗及簡單公式來設計輥輪形狀及道次參數，由於缺乏對連續輥軋製程之材料塑性流動分析能力，模具設計無法有效控制材料變形過程，必須經由多次的試模及修模，浪費時間與成本，無法得到理想的品質。本研究之目在建立連續輥軋模擬分析方法，找出模具與製程設計準則，避免使用試誤法及經驗法在設計模具上的時間浪費。

本研究以二個常用連續輥軋形狀C 型及 U型斷面為例，探討連續輥軋製程及模具設計方法。在輥花圖設計方面，考慮輥軋成形機各站輥輪中心位置連接線(輥軋基準線)變化方式、各站角度增量變化及彎角弧長控制等因素，避免各站間有過大之鈑料縱向應變。接著設計餘隙輥輪模具並使用電腦輔助分析(CAE)模擬評估設計，探討製程調整、輥花圖設計、輥輪模具設計之影響，以有效控制鈑料回彈角度、提高成品幾何精度。

由分析結果顯示，U型斷面之輥花圖設計以輥輪中心基準線下降高度為腿長3/5時，其鈑料變形最佳，依據此輥輪中心基準線變化方式進行餘隙輥輪模具設計，可有效降低縱向應變，減少腿部發生挫曲、波緣等缺陷之發生。C型斷面則以等半徑方法補償圓角長度，可降低成品之回彈角度。經由實際設計輥輪及輥軋機進行連續輥軋實驗，結果與分析相當符合，驗證本論文之方法有效可行。

Roll forming process uses a serial stands of roll to make a complex profile from a coil of metal sheet continuously. The major industrial applications include construction panel (ceiling and decoration plate), aerospace (frame of airplane), bike (rim of wheel), petroleum (large pipe by ERW). Roll forming die design is mainly dependent on the experience of the engineers nowadays. The deformation process and material flow are not considered precisely during die design stage. Die trial-out and modification cost a lot of time and money. In this research, forming process analysis and roll forming die design methods are proposed to save time and money of iterative try-outs.

In this research, C- and U-channel are adopted to present the proposed design methods of forming process and die. The roll flower design considers the roll base line, bending angle increment, and arc length compensation. The control of excess longitudinal strains is achieved via the CAE simulation. The spring back angle is controlled via the rolling process and roll flowers designs.

The results show the roll base line is optimized with an offset distance of three-fifths leg height of U-channel. The corresponding die design is able to reduce longitudinal strains and avoid leg buckling or wrinkling. For C-channel, constant radius bending design is able to control the springback angles. A roll forming press and rolls had been designed and manufactured to do roll forming experiments. The experimental results are in good agreement with the CAE prediction that verified the proposed design methods are effective and feasible.

摘要 i
ABSTRACT ii
誌謝 iii
目錄 iv
圖目錄 vi
表目錄 ix
一、 緒論 1
1.1 前言 1
1.2 文獻回顧 3
1.2.1 連續輥軋模具與道次設計 3
1.2.2 輥軋成形各種材料探討 3
1.2.3 連續輥軋成形之缺陷探討 4
1.2.4 模具最佳化設計 4
1.2.5 理論解析方法 5
1.3 連續輥軋成形技術 6
1.3.1 輥軋產品 8
1.3.2 輥花圖設計 9
1.3.3 連續輥軋模具設計 10
1.3.4 連續輥軋成形機 11
1.4 研究動機及目的 12
二、 研究理論 14
2.1 材料塑流應力理論 14
2.2 鈑材彎曲成形理論 16
2.2.1 彎曲應力與應變狀態 16
2.2.2 最小彎曲半徑 17
2.2.3 彈回現象 18
2.3 有限元素分析理論 21
三、 連續輥軋花圖與模具設計 24
3.1 U型斷面輥花圖與模具設計 26
3.1.1 鈑料參數定義 26
3.1.2 連續輥軋花圖設計 28
3.1.3 連續輥軋模具設計 32
3.2 半圓管C型斷面輥花圖與模具設計 39
3.2.1 鈑料參數定義 39
3.2.2 輥花圖圓角設計 40
3.2.3 半圓管C型斷面之模具圖 41
四、 實驗規劃與模擬方法 43
4.1 材料拉伸試驗 43
4.2 材料網格蝕刻 45
4.3 連續輥軋實驗 47
4.4 連續輥軋製程模擬方法 48
4.4.1 輥花圖分析模擬 48
4.4.2 連續輥軋製程分析模擬 48
五、 結果與討論 51
5.1 AL1050-F材料性質試驗結果 51
5.2 U型斷面輥花圖與模具設計結果 52
5.2.1 彎曲角度增量設計 52
5.2.2 輥軋基準線設計 53
5.2.3 輥輪模具設計結果 55
5.3 半圓管C型模具設計結果 60
5.3.1 等半徑設計 60
5.3.2 等弧長設計 62
5.4 U型連續輥軋實驗結果與討論 64
5.4.1 實驗與模擬分析尺寸比較 64
5.4.2 實驗與模擬分析圓角應變比較 65
六、 結論 67
七、 未來展望 68
參考文獻 69
附錄一 AL1050-F鋁材品質證明書 71
附錄二 SPCC-SD軟鋼品質證明書 72
附錄三 實驗設備規格說明 73
附錄四 COPRA操作流程 74
附錄五 輥輪模具幾何尺寸 90

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