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研究生:范鎧鏑
研究生(外文):Fan, Kai-Ti
論文名稱:採用液壓成形管件之機車車架設計
論文名稱(外文):Scooter Frame Design with the Use of Hydroforming Tube
指導教授:胡惠文
指導教授(外文):Hu, Huiwen
口試委員:黃永茂王栢村
口試委員(外文):Hwang, Yeong-MawWang, Bor-Tsuen
口試日期:2015-07-03
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:2015
畢業學年度:104
語文別:中文
論文頁數:167
中文關鍵詞:機車車架實驗模態分析結構剛性管件液壓成形有限元素分析
外文關鍵詞:Scooter frameExperimental modal analysisStructure stiffnessTube hydroformingFinite element alalysis
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本研究的目的是採用液壓成形技術,重新設計機車車架,以達到提升結構剛性15 %,同時減重 10 %。首先透過實驗模態分析,量測原始車架的自然頻率及模態振型,並藉此驗證原始車架之有限元素模型。比較分析及實驗結果可知,裸車與整車車架前12模態的自然頻率,與實驗模態分析結果差異不到6 %,驗證有限元素模型等效於實體結構,並藉此了解補強結構件於整車車架上質量與剛性的分布。應用斷面幾何設計,在不增加截面積的條件下,搭配靜態剛性分析評估以液壓成形擴大截面慣性矩的可行性,逐步設計一全新車架。最終完成之新設計車架與原車相比,靜態彎曲剛性增加39.44 % 及扭轉剛性增加15.58 %,而整車重量減少13.13 %。透過液壓成形的模擬與分析,探討車架在液壓成形階段的成形性,並藉由薄化率及成形極限圖加以評估,使得管件的薄化程度皆控制在10 % 以內,且車架主管及次管的主要應變,皆小於相應成形極限曲線80 % 的失效安全範圍,顯示在液壓成形實驗中應具有較高的成形性。最後,將成形後的管件重新放入車架結構當中,探討液壓成形後的管件於車架結構剛性與質量分布的影響。分析結果得知,成形後的液壓成形管件放入車體後,車架重量並無明顯變化,且整體剛性因成形管件厚度分布更為均勻的因素,尚有小幅提升的效果,顯示本研究的設計方法中,液壓成形管件不會因製程因素,使得車架結構物理參數產生太大變化,因此可作為往後車架變更設計的參考。

This objective of this research is to develop a new scooter frame with high stiffness and lightweight by using tube hydroforming. The ultimate goal of new frame design is to increase stiffness up 15 % and to reduce the frame weight up to 10 % in comparison with the original frame design. The original naked and completed frame design is evaluated using experimental modal analysis in the first place, since the natural frequencies and mode shapes of frame represent the distribution of frame stiffness and mass. The difference between experiment and analysis of natured frequencies results are less than 6 %. This guarantees that the finite element model is equivalent to the real frame. New frame is designed by changing the cross-sectional geometry and dimension based on the geometric calculation. Static analysis and normal mode analysis are performed to evaluate the bending stiffness, torsion stiffness and natural frequencies of the new design. The new frame is designed by changing the cross-sectional geometry and dimension based on the feasibility of tube hydroforming processes. Consequently, the bending stiffness and torsion stiffness of new frame are increased up to 39.44 % and 15.58 %, respectively. The frame weight is reduced up to 13.13 %. Finite element analysis is used to simulate the forming processes. Feasibility of tube hydroforming is based on thinning ratio and forming limit diagram. The thinning ratio of new frame tube are limited to less than 10 % in hydroforming processes. And the major strain are limited to less than safety margin of forming limit curve. This new designed parameters will be used to fabricate the prototype.

摘要 I
Abstract III
謝誌 V
目錄 VI
表目錄 X
圖目錄 XIII
第1章 緒論 1
1.1 研究動機與目的 1
1.2 液壓成形技術簡介 2
1.3 文獻回顧 3
1.4 全文概述 11
第2章 機車車架之原始設計與結構模態分析 13
2.1 機車車架實體結構與有限元素分析模型 13
2.2 單軸向拉伸實驗 16
2.3 SAPH400機械性質測試 20
2.3.1 SAPH400 厚度2.3 mm機械性質測試 20
2.3.2 SAPH400 厚度2.0 mm機械性質測試 25
2.4 結構模態分析 30
2.4.1 元素計算方式 30
2.4.2 模態分析 30
第3章 機車車架之實驗模態分析與模型驗證 37
3.1 實驗模態分析 37
3.1.1 儀器規格及選用 37
3.1.2 實驗方法與規劃 39
3.1.3 模態參數擷取 44
3.2 有限元素模型驗證 44
3.2.1 模型驗證流程 44
3.2.2 機車裸車及整車車架模型驗證 45
第4章 機車車架之斷面參數設計 66
4.1 整車補強零組件模態評估 66
4.2 主體結構斷面參數設計模評估 78
4.2.1 幾何斷面參數評估 78
4.2.2 車架斷面參數評估 81
4.2.3 車架結構變更設計 90
4.3 機車車架變更設計之結構剛性及模態分析 106
4.3.1 彎曲及扭轉剛性邊界與負載 106
4.3.2 原始車架分析結果 109
4.3.3 新式車架變更設計結果與討論 110
4.3.4 機車車架最終設計結果與討論 118
第5章 機車車架之管件液壓成形模擬與分析 125
5.1 分析模型基本架構與假設 125
5.2 材料塑性模型 126
5.3 機車車架之液壓成形 128
5.3.1 成形素材管厚度量測 128
5.3.2 車架主管之有液壓成形模擬與分析 132
5.3.2.1 車架主管有限元素模型 132
5.3.2.2 車架主管預成形邊界與負載 135
5.3.2.3 預成形分析結果與討論 137
5.3.2.4 車架主管液壓成形邊界與負載 139
5.3.2.5 車架主管液壓成形分析結果與成形參數優化 141
5.3.3 車架次管之有液壓成形模擬與分析 147
5.3.3.1 車架次管有限元素模型 147
5.3.3.2 車架次管液壓成形邊界與負載 148
5.3.3.3 車架主管液壓成形分析結果與成形參數優化 150
5.4 液壓成形車架於結構剛性的影響 156
第6章 結論與建議 161
6.1 結論 161
6.2 後續探討方向 162
參考文獻 164
作者簡介 167

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