鋁合金機車煞車拉桿之模具開發與鍛造成形

鍛造是一種使用壓力使金屬成形的加工方法，它是藉著衝擊或擠壓的方式，使金屬材料產生塑性變形，以達到所需求的形狀及機械性質的加工方法，鍛造之材質具有將晶粒充滿每一空隙部分之全密度材料現象，且亦能供應良好的尺寸條件，與其他多數之加工製程參數相較，鍛件能在所給材料發揮其最大能量之能力，並由其優秀的鍛流線獲得最大之韌性，且具有耐衝擊及耐疲勞之強度。本論文研究係針對AL6061鋁合金機車用煞車拉桿零件，利用有限元素法(Finite element method)之金屬成形模擬軟體DEFORM做為進行鋁合金鍛造製程的模擬與鍛造模具設計，並與市面上之改裝CNC煞車拉桿相互比較。傳統鍛造開模方式需依經驗並透過不斷地試作及修改模具等製作方式完成，目前鍛件設計藉由透過鍛造成形分析來設計模具，並從DEFORM鍛造成形分析過程，藉以提早發現鋁合金在熱鍛過程中經常可能產生之填料不足、疊料等問題。本研究由產品外型設計、鍛件設計、模具設計並利用DEFORM鍛造成形分析來進行鍛造模具的輔助開發，決定模具尺寸及製程參數後，製作出模具且實際進行鍛造實驗得到成品，最後為量測成品尺寸並確定是否符合產品設計之尺寸。

關鍵字

鍛造； AL6061 ；鋁合金；機車零件；有限元素分析； DEFORM

並列摘要

Forging is a processing method which uses pressure to mold metals becomes a shape. The forged material has complete grain void density, and so provides excellent dimensional properties as well as other processing parameters comparisons. Forging can give materials their best their energy capacities, and excellent forging flow lines to maximize the toughness with a high strength of impact and fatigue resistance. This study looks at AL6061 aluminum alloy motorcycle brake lever parts; using finite element analysis with metal forming simulation software, DEFORM, to carry out research into the aluminum alloy forging process simulation and die design. The research was conducted by selecting the motorcycle part of an aluminum brake lever, and comparing it with a market modification CNC brake lever, with reference to current conventional aluminum alloy forging die development methods. Traditional forging experience and constant modifications to dies and production methods were used, while at the same time verifying the finite element analysis with DEFORM software for forging feasibility by conducting simulation testing in AL6061 aluminum alloy forging. From forging design analysis through to die design and analysis with the DEFORM forging analysis process, we discovered early that in the aluminum alloy hot forging process there is a possibility of insufficient packing material, and other issues. As well as validating the feasibility of finite element analysis DEFORM software for forging analysis, this study also proposes design parameters modifications.