臺灣博碩士論文加值系統

本研究目的在研發具垂直壁補強肋鈑金折彎模具設計技術，提出建立鈑金折彎中立面CAE預測方法以精準展開鈑金折彎產品胚料尺寸。提出垂直壁鈑金波浪預成形設計，局部成形垂直壁以利後續成形材料流動。設計一可轉動折彎成形模具，以完成具鈑金波浪預成形垂直壁胚料折彎，獲得一完整具垂直壁鈑金直角折彎產品。

本研究以不同折彎半徑鈑厚比V形折彎CAE預測鈑金中立面位置，建立鈑金材料並中立面參數，以U形鈑金折彎實驗比較胚料展開尺寸正確性。經由實驗結果比較，本文以CAE建立中立面胚料展開尺寸誤差為2%，具有實用性。在無波浪預成形設計下進行折彎成形時，具垂直壁補強肋胚料在折彎處垂直壁會破裂，以本研究所提之預成形設計可以得到無破裂之，而波浪圓弧角為125.06∘、波浪圓弧半徑為3mm、波浪凸圓數為3是此波浪預成形之最佳參數。

This study focuses on the development of bending die design for a pre-bent sheet blank with reinforced ribs(vertical walls). A neutral axis prediction method for precise blank development was proposed based on the CAE simulation results. A wavy preform design method was proposed to improve the material flow for the next bending process. The design method for a bending die with rotating mechanism was proposed to get the sound bent product with reinforced vertical walls.
This thesis adopted CAE simulations to predict the neutral axes for different radius to thickness ratio V bending processed. The neutral axis position tables for tested materials were established. The predicted blank developed size for a U bent product was compared with the experimental result and showed only 2% error. The experiment results had shown the vertical walls of the reinforced blank will crack at the bending area without wavy preform. On the other hand, the vertical walls of the reinforced blank can be bent successfully without cracks if the wavy preforms were made near the bending area. The optimum design of these wavy shapes should have 3mm in radius and span angle 125.06∘. The numbers of the wavy preform should be 3 for the studied case.

摘要 i
ABSTACT ii
致謝 iii
目錄 iv
表目錄 vi
圖目錄 vii
一. 緒論 1
1.1. 前言 1
1.2. 文獻回顧 2
1.2.1. 鈑金幾何輪廓折彎製程 2
1.2.2. 回彈控制與分析 3
1.2.3. 模具與產品設計 4
1.2.4. 鈑金幾何輪廓折彎製程與模具設計 5
1.3 研究動機及目的 6
二. 研究理論 8
2.1. 鈑金折彎理論 8
2.1.1. 鈑金彈回現象 10
2.1.2. 折彎模具製程設計 12
2.2. 材料塑流應力與異向性理論 14
2.3. 有限元素分析理論 16
2.3.1. 3-PARAMETER_BARLAT 16
2.3.2. 隱式積分與顯示積分 17
三. 模具設計與成形分析 20
3.1. 鈑料與產品特徵 20
3.2. 鈑金展開設計方法 21
3.3. U形鈑金成形模具設計 22
3.4. 波浪預成形造型設計方法 23
3.4.1. 弧形波浪預成形 23
3.5. 具垂直壁鈑金折彎模具設計方法 25
3.6. 折彎成形分析參數 27
3.6.1. 材料塑流應力模式建立 29
3.7. 鈑金量測 31
3.7.1. 鈑金展開預估 31
3.7.2. 鈑金預成形輪廓 31
3.7.3. 鈑金彈回 31
3.8. 實驗規劃 32
3.8.1. U形鈑金成形實驗 32
3.8.2. 波浪預成形實驗 33
3.8.3. 具垂直壁鈑金折彎實驗 33
四. 結果與討論 34
4.1. 材料塑流應力模型建立結果與討論 34
4.2. 鈑金展開尺寸設計結果與討論 36
4.3. U形鈑金成形分析結果與討論 37
4.4. 波浪預成形造型設計分析結果與討論 38
4.5. 具垂直壁鈑金折彎分析結果與討論 45
4.6. U形鈑金成形實驗結果與討論 53
4.7. 波浪預成形實驗結果與討論 53
4.8. 具垂直壁鈑金折彎實驗結果與討論 55
4.9. 鈑金量測結果 60
4.9.1. 鈑金展開預估量測 60
4.9.2. 鈑金預成形輪廓量測 60
4.9.3. 鈑金彈回量測 61
五. 結論 62
六. 未來展望 63
參考文獻 64
附錄 67
附錄一 軟硬體版本及配備 67
附錄二 實驗儀器設備規格說明 68
附錄三 DYNAFORM Material Type-36 Model [43] 69
簡歷 72

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