微齒輸之金屬成形分析與實驗

Metal Forming Analysis and Experiment of Micro Gear

蘇裕翔(Yu-Shiang Su) ； 張朝誠(Chao-Cheng Chang)

《鍛造》 16卷4期 (2007/12) Pp. 6-11

https://doi.org/10.29791/Forging.200712.0002

摘要

本研究利用數值模擬設計微齒輪之鍛造成形，並製作模具以進行實驗驗證。其中模具幾何特徵之設計變數，包括胚料體積、胚料直徑、預形模具之圓角等，以兩個階段之常溫微鍛造成形為製程，針對模數為0.15、具有28與14齒、厚度各為0.5mm之雙層齒輪，且兩端各有2mm直徑轉軸之微齒輪元件，以可完全充填齒輸模穴與鍛最小锻造能量為目標，設計一組微鍛造預形模具。微齒輪材料為純銅C1100，而模擬所需之應力應變曲線則經由壓縮試驗獲得。研究結果顯示，數值模擬能幫助微齒輪的锻造預形設計，而微齒輪元件中之大齒輪可經微鍛造成功地成形，但其小齒輪則無法完全成形，需進一步的探討。綜合所言，微鍛造是具有潛力的金屬微齒輪成形技術。

關鍵字

微鍛造 ； 預形設計 ； 微齒輪

並列摘要

In this study, a metal forming process of a micro gear is proposed and also examined by experiments. The study uses a numerical simulation technique to design the micro forging process of the gear. The predicted profiles of the dies are then used to construct a set of dies for the experiments. In this study, the geometric features of the billet and the die are the main design variables for the preform of the micro forged gear. The variables include the volume and diameter of the billet, and the radii of the preform dies. A micro gear having two gears of 28 and 14 teeth with the module of 0.15 and the thickness of 0.5 mm is micro-forged at room temperature. The gear component also has two shafts with the diameter of 2 mn on both ends. The design target of the preform is to fulfill the complete filling of the die cavities in the finish stages of the micro forging and to minimize the energy required in entire micro forging process. The gear material is copper (C1100) and the required stress-strain curves are obtained from simple up-setting experiments. The results show that the predicted metal flows during the micro forging process are similar to those in experiments. The numerical simulation can help the design of the preforms for the micro forging gear. The 28-teeth gear can be produced by a two-stage micro forging process, but further study on the complete die filling of 14-teeth gear is still needed, In short, the micro forging process is a potential technique for the manufacturing of metallic micro gears.

並列關鍵字

Micro forging ； Preform design ； Micro gear