臺灣博碩士論文加值系統

冷軋製程中典型的潤滑型態為混合潤滑型態，所謂混合潤滑型態即是在輥軋過程中包含了軋輥與鈑材間的表面峰接觸以及潤滑劑的液動潤滑，所以界面壓力將由表面峰接觸以及潤滑油所共同承擔，因此不會因油膜過厚或油膜過薄導致無法控制表面粗度或是有磨損之現象產生。油水乳液潤滑在冷軋加工中能提供與純油潤滑近相同效果，因此，使用油水乳液潤滑不僅有良好的潤滑能力，且能提供更好的冷卻能力及成本低廉，在工業界大量的被使用。所以，研究目的將探討冷軋製程中油水乳液混合潤滑行為下之表面粗糙度。
本次研究以有限元素法結合摩潤模式進行理論分析以及配合實際冷軋實驗，完整分析在不同加工條件（包括軋輥速度與鈑材減壓率）、乳液性質（包括乳液濃度、乳液中油滴尺寸大小及油滴數量）下油膜厚度之變化，並探討潤滑油膜厚度對於軋輥力量、轉矩之影響；最後，綜合理論與實驗之結果建立起表面粗糙度與油膜厚度之關係，讓未來能夠在確定潤滑及加工條件下得出潤滑油膜厚度後，即可預測加工後之表面粗糙度。

A mixed lubrication model with oil-in-water emulsions for cold rolling processes is developed. The interface loading of this model is shared between the pressurized lubricant film in roughness valleys and contact at asperity peaks. So, it will not result in unconstrained grain deformation and severe metal-to-metal contact and consequent galling and pickup. Because the lubrication properties of emulsions are as well as pure oil, and emulsions have better cooling ability than pure oil, oil-in-water emulsions have been widely used as lubricants in manufacture today. Therefor, we investigated the surface roughness of mixed lubrication model with oil-in-water for cold rolling processes.
In present investigation, we developed an analytical model that combines finite element code with mixed lubrication analysis and a cold rolling experiment to discuss the effect of lubricant film thickness in different emulsions properties, rolling speeds and reductions. Depend on these analyses, we finally established the relationship between surface roughness and film thickness with oil-in-water emulsion in cold rolling processes.

中文摘要i
英文摘要iii
誌謝 iv
目錄v
表目錄vi
圖目錄vii
符號說明ix
一、緒論1
1.1 研究目的1
1.2 文獻回顧2
1.3 本論文之構成6
二、研究方法10
2.1 入口區的分析11
2.2 工作區的分析16
2.3 有限元素法與混合潤滑摩潤模式相結合22
三、實驗分析36
3.1 實驗設備36
3.2 實驗方法38
四、結果與討論45
4.1 與國外學者研究比較45
4.2 有限元素法結合摩潤模式與實驗之驗證50
4.3 表面粗糙度與油膜厚度關係之建立54
五、結論與建議84
5.1 結論84
5.2 建議85
參考文獻86

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