臺灣博碩士論文加值系統

本研究使用理論模型模擬無探針工具與內嵌式工具在摩擦攪拌銲接過程中之
熱傳導現象與材料流動行為。利用摩擦模型預測工具與材料間之滯滑比。模擬結
果顯示在相同擠壓力下，轉速越高滯滑比越大；而在相同工具轉速下，擠壓力越
大滯滑比越大。模擬結果亦可看出內嵌式工具之於無探針工具對材料攪動範圍較
大且材料流動速度較快。
K-type 熱電偶用於摩擦攪拌對接過程中低碳鋼試片間之溫度量測，在穩態情
況下，數值解與量測溫度甚為吻合。銲道顯現三種不同區域，包含攪拌區、熱機
影響區與熱影響區。藉由等溫線與相圖，當溫度達1394 ˚C以上時被預測為攪拌區，
此區可發現含有δ相之肥粒鐵，熱機影響區則介於上臨界溫度880 ˚C~1394 ˚C 之
間。數值與實驗結果顯示，在相同銲接情況下，內嵌式工具比純肩部工具之攪拌
區更為顯著。

In this study, a theoretical model was used to simulate the phenomena of heat
conduction and the flow behavior of material in the process of friction stir welding with
the pinless and the embedded-type tools. The friction model was employed to predict
the stick-slip ratio between the tool and the material. Theoretical results showed that
under the same downward force, the higher the rotational speed, the greater stick-slip
ratio is; and under the same rotational speed, the greater the downward force, the greater
stick-slip ratio. Results also showed that the embedded-type tool has wider stirred range
with higher flow speed of the material than that of the pinless tool.
The interface temperatures between the butt SS400 steels were measured using the
K-type thermocouples during the welding process, numerical results were in very good
agreement with the measured temperatures at the steady-state conditions. The welded
regions displayed three different zones including the stir zone, the
thermo-mechanically affected zone, and the heat affect zone. By the isotherm and the
phase diagram, the stir zone could be predicted at the temperature above 1394 ˚C
where the δ-phase of the ferrite was found, the thermo-mechanically affected zone
was between the upper critical temperature 880 ˚C and 1394 ˚C. Comparing with the
pinless tool, the numerical and experimental results showed that the embedded-type
tool had the more obvious stir zone under the same welding conditions.

誌謝 ................................................................................................................................... i
摘要 .................................................................................................................................. ii
Abstract ............................................................................................................................ iii
目錄 .................................................................................................................................. ii
圖目錄 ............................................................................................................................. vi
表目錄 ............................................................................................................................. ix
第一章 緒論 .............................................................................................................. 1
1.1 摩擦攪拌銲接概論 ........................................................................................... 1
1.2 文獻回顧 ........................................................................................................... 2
1.3 研究目的 ........................................................................................................... 5
1.4 論文架構 ........................................................................................................... 6
第二章 理論模型 ...................................................................................................... 8
2.1 三維圓柱座標系 ............................................................................................... 8
2.2 工具種類 ........................................................................................................... 8
2.3 熱傳模型 ........................................................................................................... 9
2.4 材料塑性變形產熱 .......................................................................................... 11
2.5材料塑性流動模型 .......................................................................................... 13
2.6 邊界條件-摩擦模型與熱逸散 ........................................................................ 16
2.7 數值方法 ─ 有限差分法 .............................................................................. 19
2.8 數值方法 ─ 積分法 ...................................................................................... 30
2.9 預測材料表面之流動軌跡 ............................................................................. 32
第三章 結果與討論 ................................................................................................ 43
3.1 模擬項目 ......................................................................................................... 43
3.2 工具種類對溫度與材料流動深度的影響 ..................................................... 43
3.3工具種類與轉速對表面材料滯滑比之影響 .................................................. 45
3.4 驗證點銲溫度分布與流動範圍之模擬結果 ................................................. 45
3.5工具進給速率對溫度分布的影響 .................................................................. 47
3.6 預測變態點位置與金屬成相 ......................................................................... 48
第四章 結論 ............................................................................................................ 86
4.1 結論 ................................................................................................................. 86
4.2 未來展望 ......................................................................................................... 87
參考文獻 ........................................................................................................................ 89

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