金屬箔片外緣內曲摺邊微成形與回彈之研究

Study on Stretch Flange Micro Forming and Springback of Metal Foil

邱信翔(Sin-Siang Ciou)

指導教授 ： 葉豐輝

淡江大學/工學院/機械與機電工程學系碩士班/碩士(2012年)

https://doi.org/10.6846/TKU.2012.01295

摘要

本文係探討金屬箔片外緣內曲摺邊精微成形與回彈之研究，研究中首先使用顯性動態有限元素法模擬金屬箔片外緣內曲摺邊精微成形分析，然後接續使用隱性靜態有限元素法模擬回彈分析。為驗證數值模擬之正確性，本文設計一組外緣內曲精微摺邊模具進行實驗，探討有限元素法數值模擬分析對外緣內曲摺邊精微成形之各項結果的準確性。
本研究選用壓延銅箔與SUS304不銹鋼作為分析與實驗的材料，比較數值分析與實驗之成形最大沖頭負荷、成形後回彈角度和工件外形輪廓。研究中所探討成形最大沖頭負荷，壓延銅箔的數值模擬為0.7153N，實驗為0.6815N，SUS304不銹鋼的數值模擬為1.6495N，實驗為1.7340N。本研究之成形後回彈角度有二種，分別為底邊回彈角度與側邊回彈角度，壓延銅箔的底邊回彈角度數值模擬為102.93°，實驗為103.26°，側邊回彈角度的數值模擬為101.92°，實驗為102.44°；SUS304不銹鋼底邊回彈角度數的值模擬為114.34°，實驗為112.32°，側邊回彈角度的數值模擬為113.43°，實驗為110.86°。當成形且回彈後，壓延銅箔與SUS304不銹鋼的數值模擬與實驗工件外形輪廓套疊結果亦皆一致。經由數值模擬與實驗比較，各項結果誤差皆在合理範圍內，顯示本文成果可作為相關精微成形之研究參考。

關鍵字

外緣內曲摺邊 ； 精微成形 ； 有限元素法 ； 回彈

並列摘要

This study aims to explore stretch flange micro-forming and springback of metal foil. In this study, first the explicit dynamic finite element method is applied to simulate the stretch flange micro-forming of metal foil. And then the implicit static finite element method is applied to analyze the stretch flange springback. In order to verify the accuracy of the numerical simulation, a set of dies is designed for the experiments of stretch flange micro-forming to explore the accuracy of the various results using the finite element method.
In this study, the rolled copper foil and SUS304 stainless steel are used for analyses and experiments. The maximum punch load, the springback angles, and the workpiece profile of the numerical simulation are compared with those of the experiment. The maximum punch load for rolled copper foil from the numerical simulation was 0.7153N and 0.6815N from the experiment. The maximum punch load for SUS304 stainless steel from the numerical simulation was 1.6495N and 1.7340N from the experiment. In this study, there were two types of springback angles after forming, including springback angle from bottom edge and that from side edge. For rolled copper foil, the springback angle from bottom edge from the numerical simulation was 102.93°, and 103.26° from the experiment, and the springback angle from side edge from the numerical simulation was 101.92°, and 102.44° from the experiment. For SUS304 stainless steel, the springback angle from bottom edge from the numerical simulation was 114.34°, and 112.32° from the experiment, and the springback angle from side edge from the numerical simulation was 113.43°, and 110.86° from the experiment. After forming and springback, the workpiece profiles from both the simulation and the experiment are also consistent. After the comparison between numerical simulation and experimental results, all the errors are within reasonable ranges. It shows that the results of this study can be used as a reference for future research regarding micro-forming.

並列關鍵字

Stretch Flange ； Micro Forming ； Finite Element Method ； Springback

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