臺灣博碩士論文加值系統

由於傳統型鍛加工線材端部時，係利用模具撞擊工件以達成形之目的，期間將會產生噪音，導致操作員聽力受損。且模具與工件連續的撞擊易使模具發生磨耗，亦讓工件產生成形瑕疵與精度偏離。為成形出不同幾何形狀之端部，須相應製作多種模具，增加產品成本。
為此，本研究嘗試建立一套無需成形模具且具變化性之端部加工製程，該製程係以無模具抽製製程為基礎，給定一端部幾何，依各位置之截面變化得出應變分布，再給定一負荷設定，即可得各部位的應力分布。將各部位之應力應變值與材料各溫度之應力應變特性曲線加以比對，即得出該端部位置之溫度分布情形。於抽製過程中，於線材中間藉由加熱線圈以及水冷卻，當工件發生破斷，同時該區域達到所需之溫度分布，即可獲得所給定之端部幾何。其中，實驗之感應線圈與水冷卻的位置，及其加熱功率、冷卻水流量和冷卻時間等參數均藉由有限元素法模擬規劃。
本研究以抽製線材端部具錐度0.3的線材幾何為例，探討不同負荷設定、不同抽製速度以及不同初始溫度分布對成形結果的影響以驗證此製程的可行性。實驗結果得知，當負荷設定越大，所得之成形錐度則越大。且實驗中所得之抽製負荷皆為一近似水平之直線，不同於拉伸試驗的倒V形負荷變化；另於抽製速度方面得知，降低抽製速度，所成形之錐度幾何則變小。而由不同初始溫度分布的抽製結果得知，越增加冷卻時間，將使線材初始溫度分布下降至與最後成形所需之溫度分布越接近，越能獲得較小之錐度幾何。除此，本研究尚應用於非錐度之端部成形，作為驗證所建立的系統與方法足以提供業者做多變性的端部加工。

Traditional swaging always causes die to wear. The worn dies would make dimensions of workpiece end to deviate. Besides, in the forming process, the loud noise would damage operators’ hearing. On the other hand, workpieces with different end geometry should be individually swaged by corresponding dies, which furthermore cost a lot.
Under the consideration of cost, this study would develop a process, which is based on dieless drawing and able to manufacture the end of workpieces without dies. For a given shape of wire end, the on-site strain distribution can be calculated according the area reduction of each cross-section. Similarly, for a given drawing load, the on-site stress can also be calculated with the cross-section area. Combining the strain and the stress for each cross-section, a strain-stress distribution can be created. During the drawing process, the wire’s temperature profile can be achieved by a heating and cooling system. Once the wire is apart, the ends of wire were therefore formed to the given shape. For the setups in the experiment, not only the position of induction heating coil and cooling area, but also the heating power as well as cooling water flow and time are all determined by finite element method.
As an example, a taper of 0.3 was taken to form the ends of an AISI-1045 wire. The influences of load, drawing velocity, and initial temperature profile on the forming results were investigated. According the results of experiment, increasing the load raises the formed tapers. And every loads over the drawing stroke looks like a horizontal line, which is different from that in the tensile test showing an inverse V shape. In addition, reducing the drawing velocity decreases the formed tapers. Furthermore, the lower the initial temperature profiles, the less the taper of wire ends can be obtained.
In addition, to demonstrate the method proposed by this study and offer another reference for the industry to manufacture the end of wire, this study also try to form an end without taper.

謝辭 i
摘要 iii
Abstract iv
目錄 vi
表目錄 viii
圖目錄 ix
符號表 xiii
1 前言 1
1.1 文獻回顧 2
1.1.1 鍛頭成形 2
1.1.2 旋轉型鍛 3
1.1.3 無模具抽製法相關文獻 5
1.2 研究目的與方法 12
2 研究設計 14
2.1 端部幾何與溫度分布 16
2.2 實驗設定與規劃 20
2.2.1 機構 20
2.2.2 電控設備 24
2.2.3 溫度控制系統與量測元件 27
2.2.4 運動控制程式 30
2.2.5 實驗流程與設定 30
2.3 溫度分布有限元素分析設定 32
2.3.1 模型幾何網格分割與特性建構 32
2.3.2 邊界條件之設定 34
3 結果與討論 35
3.1 實驗設計 35
3.2 不同負荷設定之溫度分布結果 41
3.3 不同負荷設定之成形幾何 48
3.4 T(X, T2)溫度對成形幾何之影響 58
3.5 抽製速度對成形幾何之影響 66
3.6 溫度分布之偏差 74
3.7 不同端部幾何之應用 76
4 結論 83
5 參考文獻 85
附錄A 計時繼電器與配電示意圖 88
附錄B 感應加熱功率與熱對流係數之校正 89
附錄C 各量測點之模擬與實驗溫度變化 92
附錄D 端部幾何之對稱性 97
附錄E 負荷設定[wa12] 99

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