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研究生:陳庭育
研究生(外文):Tingyu Chen
論文名稱:水龍頭之液壓與彎管成形模擬分析與實驗
論文名稱(外文):Simulation and Experiment of Hydroforming and Bending for Making a Faucet
指導教授:胡惠文
指導教授(外文):Huiwen Hu
學位類別:碩士
校院名稱:國立屏東科技大學
系所名稱:車輛工程系所
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:2013
畢業學年度:101
語文別:中文
論文頁數:76
中文關鍵詞:液壓成形彎管成形內壓力軸向缸多段線性塑性模組有限元素模型厚壁管理論厚度分佈幾何尺寸
外文關鍵詞:HydroformingBendingInternal pressurePunchPiecewise linear plasticity modelFinite element modelTheory of thick-wall cylinderDistribution of thicknessProfile dimension
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本論文研究目的為透過液壓與彎管成形的技術來製造一水龍頭。傳統水龍頭多採用鑄造的方式來進行製造,但其製造過程必須在高溫且後處理時有高粉塵汙染。因此在製造水龍頭時採用液壓與彎管成形較傳統鑄造來的乾淨、精準且有效。本論文中所採用成形素材管為SUS304不銹鋼,並透過材料拉伸試驗來獲得其材料機械性質。本研究採用ANSYS/LS-DYNA進行有限元素分析模型建立,模型包含管件(Tube)、模具(Die)、側缸(Punch)等。分析中以多段線性塑性模組將SUS304不銹鋼材料真實應力應變曲線輸入,以模擬出材料於塑性區段的變形行為。成形初始壓力則採用厚壁管理論來進行計算。然而水龍頭的成形參數不只有內壓力,也包含了軸向進給與背桿支撐力。因此透過模擬分析的方式找出最佳的成形負載路徑。彎管成形方面也可透過模擬分析的方式找出內支桿放入管件中最佳的支撐位置。根據分析的負載參數來進行水龍頭試作實驗,透過分析與實驗的厚度分佈與幾何尺寸比對來驗證分析之準確性。
The purpose of this research is to develop the technique of hydroforming and bending for making a faucet. Traditionally, the faucet is made using casting which is a fabrication approach involved high temperature and dusting in post tooling. Hydroforming and bending provide more clean, accurate and efficient approach than casting in fabricating faucet. The tube made from stainless steel SUS 304 is used in this study. Its mechanical properties are obtained using tensile test. Finite element model, including tube, dies and punches, are established using a commercial code ANSYS_LS-DYNA. The true stress-strain curve is then used to enter the commercial code which is used to simulate the plastic deformation of material during the forming process by adopting piecewise linear plasticity model. The initial internal pressure is designed by using the theory of thick-walled cylinder. However, the hydroformibility of faucet depends not only on internal pressure but also on axial punches and counter punch. Simulation is therefore used to find the optimal loading conditions. The simulation of bend forming is also performed to find the optimal position of supported rod which is placed inside the tube.
Experiment is performed to fabricate the prototype of faucets using the simulated loading parameters. The results obtained from simulation and experiment show that good correlations of the distribution of thickness and the profile dimension are obtained.

摘要.... ...................................................I
Abstract..................................................II
謝 誌.....................................................IV
目 錄......................................................V
表目錄....................................................VII
圖目錄...................................................VIII
第1章 緒論..................................................1
1.1 研究動機與目的.........................................1
1.2 液壓成形技術概述........................................2
1.3 彎管成形技術概述........................................3
1.4 文獻回顧..............................................6
1.5 全文概述..............................................8
第2章 水龍頭之成形模擬與分析...................................9
2.1 分析模型基本架構與假設...................................9
2.2 分析模型之建構........................................10
2.2.1 建立模型幾何外型...................................10
2.2.2 網格規劃.........................................10
2.2.3 水龍頭成形邊界與負載條件............................13
2.2.3.1 水龍頭之液壓成形...............................13
2.2.3.2 水龍頭之彎管成形...............................21
2.2.4 材料與機械性質測試.................................25
2.3 材料之塑性模型........................................30
2.4 LS-DYNA模擬成形之控制參數..............................32
第3章 水龍頭成形實驗.........................................36
3.1 水龍頭之液壓成形實驗...................................36
3.2 水龍頭之彎管成形實驗...................................46
3.3 水龍頭成形實驗結果.....................................49
3.3.1 水龍頭液壓成形實驗結果..............................49
3.3.2 水龍頭彎管成形實驗結果..............................56
第4章 分析結果與討論.........................................59
4.1 水龍頭液壓成形分析與實驗比對.............................59
4.2 水龍頭彎管成形分析與實驗比對.............................67
第5章 結論.................................................71
5.1 成果概要.............................................71
5.2 後續探討方向 ..........................................72
參考文獻...................................................73
作者簡介...................................................76

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