本論文即以飛機製造業生產之鋁合金蒙皮零件“機翼前緣整流罩”所使用的模具與製程來做研究的方向。一般超塑成形製程多以平鈑直接吹氣成形，成形模具深寬比較小，而本研究之機翼前緣整流罩所設計出來的模具深寬比較大，無法使用平鈑吹製製程，為了改善深寬比，在執行超塑成形之前，先將鋁合金5083鈑材進行預成形折彎加工。折彎加工目的為了使鈑材在尚未執行超塑成形前，即可預先縮短材料與成形模具之間的成形距離，使工件能順利完成超塑成形。另外也設計出可減少成形距離的製程，如兩階段氣吹成形製程及熱引伸輔助製程等。
由於全尺寸實驗所需耗費的成本較大，如電費、鋁合金鈑材等，加上實驗時間須配合漢翔生產線的空餘時間，所以能實驗的次數有限，為了減少成本以及增加實驗效率，本研究將原模具設計成縮小版尺寸，並對母模成形輪廓做設計，如雙峰等高設計、V形底部R角放大設計、V形底端降低設計等，分析各製程及模具設計的優劣，設計出最佳的成形模具製程。

The study focuses on the mold and manufacturing process of aluminum alloy spare parts “airliner wing’s fairing cover” for aircraft manufacture industry. Superplastic forming manufacturing process usually using aluminum alloy plate and the molding contour is designed by low aspect-ratio. In this study, the airliner wing’s fairing cover molding contour is designed by high aspect-ratio. The aluminum alloy plates can’t be directly used for superplastic forming process. In order to improve the design of high aspect ratio, the SP5083 sheets bended for a preforming before superplastic forming process. The bending preforming in order to reduce the forming distance between SP5083 sheet and mold, then the spare parts fairing cover can be successfully produced. And there are several designs to reduce the forming distance manufacturing process, such as Two-Stage Superplastic Forming and Hot Draw Mechanical Preforming, etc.
Because of large-sized mold and the experments need to comsume large cost, such as electricity bill and aluminum sheet meterials, etc. And the experiment coordinate with AIDC production line free time. So the experiment have restriction on the number. In order to reduce costs and increase the efficiency of the experiment. In this study, the mold is designed a small-sized model. And the mold contour also is designed, different model such as Two-cavity designed have same depth, enlarge the bottom of the V-shape preforming curvature radius, bottom of the V-shape preforming designed lower, etc. Analyzing the merits of the manufacturing process and mold design and choosing the best mold and manufacturing process.

摘要 i
Abstract ii
誌 謝 iii
目錄 iv
圖目錄 viii
表目錄 xvii
符號說明 xx
第一章 緒論 1
1-1 前言 1
1-2 超塑性成形理論與應用 2
1-2-1 超塑性(Superplasticity) 2
1-2-2 超塑材料之性質與必要條件 4
1-2-3 超塑材料之應用方向 8
1-3 超塑成形製程方式簡介 10
1-3-1 一般超塑性與傳統機械加工方式比較 10
1-3-2 一般超塑性缺點 11
1-4 超塑成形製程方法與工作原理 12
1-4-1 傳統超塑成形(CSPF)的工作原理 12
1-4-2 兩階段超塑成形(TSGF)的工作原理 13
1-4-3 熱引伸機械成形(HDMP)的工作原理 14
1-5 文獻回顧 14
1-5-1 超塑成形使用之製程方法 14
1-5-1-1 傳統超塑成形(CSPF)製程方法 16
1-5-1-2 兩階段超塑成形(TSGF)製程方法 17
1-5-1-3 熱引伸機械成形(HDMP)製程方法 18
1-5-1-4 各製程結果討論 21
1-5-2 熱引伸機構之夾料板力量 23
1-5-2-1 夾料板面積與夾料力量探討 24
1-5-3 全尺寸工件之室溫引伸輔助氣壓成形製程 26
1-5-3-1 全尺寸工件介紹 26
1-5-3-2 室溫引伸輔助氣壓成形實驗結果 30
1-6 研究動機及目的 34
第二章 理論探討 35
2-1 成型理論 35
2-1-1 超塑成形組成方程式 35
2-1-2 長形方盒壓力-時間計算理論 37
2-1-3 圓錐形體壓力-時間計算理論 39
2-2 空孔形成機制 41
2-2-1 空孔成核 41
2-2-2 空孔結合 43
第三章 實驗架構與實驗方法 44
3-1 實驗設備 44
3-1-1 全尺寸實驗設備 44
3-1-2 縮小版實驗設備 49
3-1-3 通用實驗設備 52
3-2 實驗材料 57
3-3 厚度減薄估算方法 58
3-3-1 成品厚度估算 58
3-3-2 減薄率 59
3-4 V形折彎預成形方法 60
3-5 製程與模具設計 63
3-5-1 兩階段氣壓成形製程 66
3-5-2 全尺寸縮小四倍熱引伸製程 76
3-5-3 全尺寸縮小四倍母模雙峰等高模具設計 86
3-5-4 全尺寸縮小四倍母模V形底端降低模具設計 101
3-6 實驗流程 107
第四章 實驗結果與討論 108
4-1 全尺寸模具 108
4-1-1 兩階段氣壓成形實驗結果與討論 108
4-1-2 全尺寸模具結論 112
4-2 原尺寸縮小四倍模具 113
4-2-1 熱引伸輔助氣壓成形製程 113
4-2-2 母模雙峰等高模具 123
4-2-3 母模V形底端降低模具 131
4-2-4 原尺寸縮小四倍模具結論 138
第五章 結論與未來展望 139
5-1 結論 139
5-2 未來展望 141
參考文獻 142

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