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研究生:鄭凱騰
研究生(外文):Kai-teng Jhang
論文名稱:三角型斷面之連續輥軋模具與機台設計
論文名稱(外文):Cold roll-forming die and machine design of triangular-cross section
指導教授:許進忠許進忠引用關係
指導教授(外文):Jinn-Jong Sheu
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
畢業學年度:100
語文別:中文
論文頁數:81
中文關鍵詞:連續輥軋成形成形工法設計輥花圖設計輥軋導引線輥輪設計輥軋機台設計
外文關鍵詞:cold roll-formingroll pass designroll flower designbase guiding lineroll designcold roll-forming machine design
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連續輥軋是一種快速生產複雜斷面鈑金的成形方法,目前模具設計開發大多仍以依賴經驗及簡單公式來設計輥輪形狀及道次參數,缺乏材料流動分析能力,模具設計無法有效控制材料變形過程,經多次試模及修模,浪費時間成本,無法達到理想的品質。本研究以產業應用產品三角形斷面為研究載具,提出模具設計與製程設計準則,進行製程模具設計方法及成形機台設計。製程設計包含工法及輥花圖設計,由產品展開計算胚料鈑寬,以成形極限預估成形道次數目,考慮輥輪干涉進行花圖折彎順序設計,輥軋基準線變化影響,設計各站成形角度增量變化,加入板料預折彎輥輪設計,使用電腦輔助分析(CAE)模擬評估輥花圖及輥輪模具設計。
由分析結果顯示,三角形斷面(三角骨架)之輥花圖設計分別以等角度及混和角度增量展開方法,其鈑料應變分佈均勻;並由輥花圖加入重心導引線,可有效平緩應變趨勢,並以此花圖重心導引線變化方式進行輥輪模具設計。加入預反折彎輥輪模具設計,減少成形彈回缺陷。有限元素分析可預測腿部發生挫曲、波緣等缺陷,並提供模具設計參考。配合連續輥軋模具設計,完成模組式連續輥軋機設計,以鋁擠型為組成輥軋機結構,加上動力、傳動及控制模組,建立一可調整式輥軋原型機,使用鋁鈑及鋼鈑進行實驗,得到之輥軋品符合產品尺寸規格,驗證本論文之方法有效可行。
Roll-forming process is a quick way of manufacturing complex shape sheet metal. The roll design and roll flower (roll pass) design are dependent on the experiences because of the forming process analysis is very difficult. Die try-out and modification is very time consuming and costive process. This research proposes die and process design of making a triangular section product. Cold roll-forming rolls and machine are designed using the proposed criteria of pass design and roll design. The width of sheet blank is developed from the product geometry, the pass number required is determined using forming limit, and the roll flower of bending sequence should be interference free. CAE simulation was adopted to evaluate the all designs of roll flower and rolls.
The results showed the constant and the hybrid angle increment designs are able to achieve more uniform stain distribution of sheet metal. The base guiding line refers to the gravity center of cross-section of each stand is able to distribute the strain increment smoothly. A pre-bending design was proposed to reduce the springback defect. CAE simulation is able to predict the defects of leg buckling and waving, which is useful for redesign of die. A roll-forming machine composed different modules was designed and built based on the designs of roll pass and dies. The structure of machine was built with hot extrusion bars of aluminium. The motor, power transmission, and the control modules were installed to establish an adjustable proto-type machine for experiment. The dimensions of product made with this machine were good enough as requirement. It shows the proposed method is feasible.
目錄
摘要 ii
ABSTRACT iii
誌謝 iv
目錄 v
表目錄 viii
圖目錄 ix
一、 緒論 1
1.1 前言 1
1.2 文獻回顧 3
1.2.1 連續輥軋製程分析設計 3
1.2.2 輥軋成形缺陷探討 3
1.2.3 連續輥軋模具參數設計 4
1.3 研究動機及流程 6
二、 研究理論 8
2.1 鈑金彎曲成形理論 8
2.1.1 彎曲應力與應變狀態 8
2.1.2 彈回現象 9
2.2 有限元素分析理論 10
2.3 連續輥軋成形理論 10
2.3.1 鈑料展開計算 10
2.3.2 成形道次數 13
2.3.3 輥花圖折彎方法 16
2.3.4 輥花圖折彎順序選用 17
2.3.5 輥花圖基準線 18
2.3.6 輥花圖折彎角度增量 20
2.3.7 輥輪模具計算 21
三、 三角型斷面連續輥軋模具與原型機設計 23
3.1 基本特徵元素輥軋折彎 23
3.1.1 基本特徵元素幾何與鈑料計算 24
3.1.2 基本特徵元素幾何模具設計 25
3.2 三角型斷面成形工法設計 26
3.2.1 產品幾何與鈑料展開 26
3.2.2 成形道次數設計 26
3.3 三角型斷面輥花圖設計 29
3.3.1 花圖折彎順序 29
3.3.2 花圖輥軋基準線設計 30
3.3.3 花圖成形角度增量設計 31
3.4 三角型斷面模具設計 32
3.4.1 輥輪模具大小設計 33
3.4.2 輥輪模具無反折及預反折設計 34
3.4.3 輥輪模具分割及合併設計 35
3.5 三角型斷面連續輥軋原型機設計 36
3.5.1 輥軋機模組設計 38
3.5.2 輥軋機心軸設計 49
3.5.3 輥軋機傳動機構設計 51
3.5.4 輥軋成形機組裝程序 54
3.5.5 輥軋機控制系統簡介 57
四、 分析與實驗驗證 58
4.1 連續輥軋製程模擬方法 58
4.1.1 建立材料塑流應力數據 58
4.1.2 輥花圖縱向應變模擬 59
4.1.3 連續輥軋製程分析模擬 60
4.2 連續輥軋實驗 61
4.2.1 材料網格蝕刻 61
4.2.2 機台測試規劃 64
4.2.3 連續輥軋實驗 64
五、 結果與討論 65
5.1 基本特徵元素分析結果 65
5.1.1 工法評估與成形分析寬度應變比較 65
5.1.2 花圖幾何分析與成形分析縱向應變比較 66
5.1.3 花圖幾何分析與成形分析厚度應變比較 67
5.2 三角型斷面分析結果 68
5.2.1 輥花圖輥軋幾何分析 68
5.2.2 無反折與預反折模具設計結果 72
5.2.3 三角型斷面幾何模擬結果比較 73
5.3 實驗分析與比較 74
六、 結論 76
七、 未來展望 77
參考文獻 78
參考文獻
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