臺灣博碩士論文加值系統

皮帶輪旋壓成形製程中，輥輪是使旋壓製程取得良好結果的關鍵因素之一，皮帶輪的外徑尺寸、輪溝形狀及表面粗糙度都靠輥輪來完成。加工時，輥輪與胚料作局部接觸，承受著巨大的接觸壓力、劇烈的摩擦力和較高的工作溫度，所以輥輪的材質應具有足夠高的強度、硬度、強韌性和耐磨性。根據產品設計圖對皮帶輪溝型及溝角的要求，而設計輥輪的形狀尺寸，並且根據旋壓成形機對輥輪最大及最小尺寸的要求，來確定輥輪的直徑，為了增加輥輪的使用壽命、降低表面粗糙度，通常輥輪表面要進行拋光。
本文以有限元素法為基礎，利用DEFORM-3D有限元素分析軟體進行三維旋壓製程模擬，並探討輥輪在不同的幾何形狀及定剪摩擦因子下，胚料的成形性差異，以及模具應力分析，分析模具的受力情形。最後進行皮帶輪半成品的金相實驗，藉著金相試驗之巨觀組織，觀察材料內部之缺陷、結晶粒大小及材料破壞之情形。
經有限元素法模擬分析後，觀察半成品外形得知，跟實際加工後的工件形狀很接近，並且在提高定剪摩擦因子與加大輥輪圓角半徑後，輥輪的應力有提高的現象，得知這兩種製程參數皆會影響輥輪的應力狀態。因此，輥輪表面的粗糙度、外形尺寸的確會對旋壓時的材料流動與成形負荷造成影響。

In pulley spinning process, roller is the key factor to achieve good product because pulley diameter size, shape and surface roughness all result from roller’s geometry and quality. During spinning process, roller and blank contact with each other in local area that will result in a huge contact pressure, an intensive frictional force and a high temperature. Therefore, the roller material should behave high strength, hardness, toughness and wear resistance. The design of roller geometry and size are based on the required product specification and forming machine tool such as the pulley groove-ditch corner in accordance with the largest and the smallest roller sizes of the spinning machine. In order to increase the roller life and reduce the surface roughness of pulley, the roller surface should carry out polishing.
This thesis utilized DEFORM-3D finite element analysis software for 3D simulation of spinning process to explore process parameters related to pulley spinning process such as roller in different geometric shape and in different constant friction coefficient. The die stress analysis was also conducted. Finally, the macrostructures of semi-finished pulley such as macro organization, internal defects and crystal grain size were investigated by experiments.
The simulation results show that the pulley preform (after the first step spinning) is close to experiment and the maximum roller stress increases when increasing constant friction coefficient and fillet radius of roller. Therefore, the roller geometry and surface condition have great influence on material flow and forming force in pulley spinning process.

中文摘要 II
英文摘要 III
誌謝 V
目錄 VII
表目錄 VIII
圖目錄 IX
1-1 前言 1
1-2 研究動機與目的 1
1-3 文獻回顧 1
1-4 本文架構 4
第二章 旋壓簡介 6
2-1 旋壓成形簡介 6
2-2 旋壓皮帶輪 6
2-3 皮帶輪種類 8
2-4 皮帶輪各部位名稱 9
2-5 製程條件 10
2-6 旋壓成形機發展概況 11
第三章 電腦模擬 14
3-1 有限元素法簡介 14
3-2 模擬條件規劃 14
3-2-1 運動型態設定 14
3-2-2 模擬參數設定 17
3-3 DEFORM-3D Ver 6.1操作程序與相關設定 20
第四章 結果與討論 32
4-1皮帶輪之DEFORM-3D模擬結果 32
4-1-1 皮帶輪製程立體圖 32
4-1-2 定剪摩擦因子0.5 49
4-1-3 輥輪R角半徑為1.2mm 53
4-2 輥輪之應力分析 57
4-3 金相實驗 59
4-4 旋壓皮帶輪產品之微硬度分析 61
4-5 等效應力與等效應變分析 64
4-6 微硬度值理論模擬與實驗結果 67
第五章 結論與建議 68
5-1 結論 68
5-2 建議 68
參考文獻 69
附錄 71
簡歷 83

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