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研究生:黃金通
研究生(外文):Kim-Thong Bong
論文名稱:沖壓製程對電磁鋼片加工硬化區之研究
論文名稱(外文):Work Hardening Zone of Electrical Steel in Punching Process
指導教授:蔡曜陽蔡曜陽引用關係
指導教授(外文):Yao-Yang Tsai
口試委員:陽毅平李貫銘陳國民
口試委員(外文):Yee-Pien YangKuan-Ming LiKuo-Min Chen
口試日期:2015-07-28
學位類別:碩士
校院名稱:國立臺灣大學
系所名稱:機械工程學研究所
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:2015
畢業學年度:103
語文別:中文
論文頁數:98
中文關鍵詞:沖孔定子槽形鐵損伺服沖床倒角半徑夾角角度
外文關鍵詞:Work hardeningStator slotIron lossServo pressFillet radiusAngle between two lines
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電磁鋼片在加工過程中會因為殘留應力以及塑性應變的產生造成電磁特性惡化進而影響馬達的整體效率。直到現在,電磁鋼片的電磁特性在加工過程中惡化的情況仍然無法預估及掌握。這是造成電動機生產後實際效率與設計效率產生落差的原因之一。
為了更加了解電磁鋼片在沖壓加工製程中造成的影響,本研究設計了一套定子槽形沖壓模具,包括了82°、86.7°、88°的夾角角度以及0.25mm、1mm、2mm、6mm的倒角半徑。
在固定槽形的條件下,分析沖頭速度、壓料板壓力、反壓板壓力以及沖頭行程模式對加工硬化面積的影響。
實驗結果顯示提高沖頭速度、沖頭行程模式為振動模式、在適當的壓料板壓力及反壓板壓力下,電磁鋼片沖壓切邊於直線部位的加工硬化面積相較於其他沖壓參數明顯降低。本實驗的最佳沖壓參數相較於本實驗的其他沖壓參數,最大可減少0.0379mm2的加工硬化面積,相當於減少56%。
另外在固定沖壓製程參數的條件下,分析定子槽夾角角度與倒角半徑對加工硬化區的影響,實驗結果顯示倒角半徑越大在倒角部位會造成越小的加工硬化面積,最大減少1.340mm2的加工硬化面積,相當於增加92%;夾角角度越大則有減小加工硬化區的效果,最大減少0.5202mm2的加工硬化面積,相當於減少36%


In the punching process, the iron loss of the electrical steel sheet will increase dramatically due to the plastic strain. So far, the iron loss effect of electrical steel sheet in the punching process may be difficult to predict and control. This effect also reduces the overall efficiency of the motor.
In this research, the plastic strain of electrical steel in the punching process is determined by the working hardening theory.
In order to create the plastic strain, a punching mold of stator slot was designed, including 82.0°, 86.7°, 88.0° angle between two lines and 0.25mm, 1mm, 2mm, 6mm fillet radius. Under the fixed geometry, the influence of punching speed, blank holder pressure, counter punch pressure and punching mode on hardening area are measured.
The results show that the hardening area is reduced by raising the punching speed, punching with vibration mode, and punching with appropriate blank holder and counter punch pressure.
In addition, under the fixed punching parameters, the influence of the angle between two lines and the fillet radius of the stator slot on hardening area are analyzed. The hardening area decreases along with the larger fillet radius and the larger angle between two lines.


口試委員會審定書 I
誌 謝 II
摘 要 IV
Abstract V
目 錄 VI
圖目錄 IX
表目錄 XIII
第一章 緒論 1
1.1 研究背景 1
1.2 文獻回顧 3
1.3 研究動機與目的 6
1.4 論文大綱 8
第二章 相關技術理論介紹 9
2.1 電動機的基本構造 9
2.2 電動機的耗損分類 9
2.2.1 定子與轉子繞組耗損(Stator Losses And Rotor Losses) 10
2.2.2 定子及轉子鐵心耗損(Core Losses) 11
2.2.3 雜散耗損(Additional Load Losses) 13
2.2.4 風磨耗損(Windage and Friction) 13
2.3 電動機定子製程特性分析 14
2.3.1 電磁鋼片單片切割 16
2.3.2 疊層鉚合及焊接 17
2.3.3 退火熱處理 17
2.3.4 繞線製程 18
2.3.5 固定封裝 18
2.4 沖壓理論 18
2.4.1 沖壓參數的意義 18
2.4.2 精密下料的工作原理 20
2.4.3 沖壓斷面之分析 20
2.4.4 沖壓過程中金屬的塑性變形 22
2.4.5 沖壓過程中金屬的加工硬化 24
第三章 實驗步驟與方法 25
3.1 實驗規劃流程圖 25
3.1.1 沖壓製程參數對電磁鋼片的影響 26
3.1.2 定子槽幾何變化對電磁鋼片的影響 32
3.1.3 電磁鋼片的評估方法 33
3.2 實驗材料、實驗設備與量測儀器 35
3.2.1 實驗材料 35
3.2.2 實驗設備 36
3.2.3 量測儀器 43
3.3 實驗方法與步驟 45
3.3.1 建立塑性應變與電磁特性關係實驗步驟 45
3.3.2 建立塑性應變與加工硬化關係實驗步驟 47
3.3.3 沖壓製程參數對電磁鋼片的影響實驗步驟 48
3.3.4 定子槽幾何變化對電磁鋼片的影響實驗步驟 49
第四章 實驗結果與討論 50
4.1 建立塑性應變與電磁特性關係 50
4.2 建立塑性應變與加工硬化關係 50
4.3 沖壓製程參數對電磁鋼片加工硬化區的影響 52
4.3.1 假設與定義 52
4.3.2 沖頭速度對加工硬化面積之影響 56
4.3.3 壓料板壓力對加工硬化面積之影響 62
4.3.4 沖頭行程模式對加工硬化面積之影響 67
4.3.5 小結 71
4.4 定子槽形幾何變化對電磁鋼片加工硬化區的影響 72
4.4.1 定子槽寬度對加工硬化面積之影響 72
4.4.2 定子槽倒角半徑對加工硬化面積之影響 75
4.4.3 定子槽夾角角度對加工硬化面積之影響 77
4.4.4 小結 79
4.5 不同沖壓製程參數與定子槽形幾何對電磁鋼片加工硬化區之影響 80
4.6 討論 82
4.6.1 電磁特性分佈圖的推估 82
4.6.2 本研究可能出現的誤差 82
4.6.3 最大加工硬化距離的統計 83
第五章 結論與未來展望 91
5.1 結論 91
5.2 未來展望 92
參考文獻 94
作者簡歷 98


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