臺灣博碩士論文加值系統

目前協祥所使用的花鍵軸在三道次冷擠製程中，主要遇到的問題為模具磨耗效應顯著使得模具壽命過短。為解決此問題，本研究利用有限元素軟體 Deform 3D 來驗證文獻及協祥現有的花鍵齒軸冷擠製程，藉由模擬的結果，發現目前協祥使用的三道次冷擠製程方式，成形負載出現峰值的次數相對較多、成行負載不穩定。本研究同時透過修改目前協祥三道次擠製模具的幾何參數與圓棒素材的直徑來增加成形負載的穩定。根據最後模擬的結果顯示︰透過對模具幾何參數的修改，能夠在材料成形的安全範圍內，有效降低成形負載峰值出現的次數，增加負載之穩定性。再者，可降低成形負載的平均值，減輕磨耗的效應、延長模具的使用壽命。

The gear spline shafts were manufactured by the Shye-Shyang Company at present. They were produced by a three-pass cold extrusion. However, the die wear is of increase so that the die life is of decrease when using this method. To solve the problem, this study applied a finite element analysis software, Deform 3D, to simulate this method. Simulation results showed that the peak value of the forming loading shows more times during the three-pass cold extrusion. This causes an instability of forming loading. Hence, this study modified geometric parameters of the three-pass extrusion die and diameter of a circular rod with metal to increase the stability of forming loading. Simulation results demonstrated that the basic of the modified geometric parameters of the die, the peak value of forming load appears less times as compared with original parameters of the die during the safe range of metal forming. Moreover, this modification also decreased the mean value of forming loading, reduced wear effect of die, and extended the service life of die.

中文摘要 i
英文摘要 ii
誌謝 iii
目錄 iv
表目錄 vi
圖目錄 vii
第一章 導論 1
1.1前言 1
1.2 文獻回顧 2
1.3 研究範疇 4
第二章 塑性加工 5
2.1塑性加工種類 5
2.2塑性加工系統 6
2.3塑性變形 8
2.3.1 材料拉伸試驗 8
2.3.2 塑性變形機制 9
2.3.3 塑流應力 10
2.3.4 金屬延展性 11
2.3.5 三維應力場 11
2.3.6 降伏準則 12
2.4成形界面的機械效應 13
2.4.1 界面摩擦力 13
2.4.2 磨耗 14
2.5材料破壞 17
第三章 齒輪的擠製 18
3.1齒輪的製造 18
3.2擠製與抽製的原理 19
3.2.1 擠製的簡介 19
3.2.2 抽製的簡介 20
3.3成形的基本觀念 21
3.3.1 金屬材料的流動 21
3.3.2 應力場的分析 22
3.3.3 成形負載 22
3.4花鍵齒軸擠製過程 23
3.5模具磨耗 32
第四章 成形理論 33
4.1上邊界法則 33
4.2有限元素法 36
4.2.1 有限元素法原理 36
4.2.2 DeForm 3D軟體簡介 37
4.3材料破裂範圍預測 38
第五章 模擬與討論 41
5.1模擬的規劃 41
5.2模擬元件的架構 45
5.3模擬結果與討論 48
5.3.1 成形負載 48
5.3.2 齒頂處之材料填充 50
5.3.3 成品之破裂因子累積 54
5.4擠製成形因子修改 57
5.4.1 改變素材直徑 58
5.4.2 改變模具齒頂圓直徑 62
5.4.3 改變模具齒形形狀 70
第六章 結論與建議 86
6.1結論 86
6.2建議 87
參考文獻 88
附錄 90

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