有限元素分析嵌埋式金屬複合塊材之埋頭釘釦鍛造成形

Finite Element Analysis of Countersunk Studs Hot Forged in Core-Shell Type Metal Composite Bulks

范光堯(Fann, Kuang-Jau) ； 賴惟昂(Lai, Wei-Ang)

《鍛造》 24卷2期 (2015/07) Pp. 13-18

摘要

本研究嘗試建立一嵌埋式金屬複合塊材鍛件的製程，並以埋頭釘釦鍛件為例，將置於套筒狀包材內的芯材於模具中藉沖頭的移動，將成形與包覆於一衝程內完成，製成一嵌埋式金屬複合塊材鍛件。研究以鋁合金6061為包材，7075為芯材，並以包材底部厚度、包材與芯材二端部間高度差、成形溫度以及剪力摩擦係數為製程參數，藉由有限元素軟體分析該製程的可行性，結果顯示：包材底部厚度需高於模具肩部，以避免包材側壁產生褶料缺陷。同時，鍛造溫度越高，除沖頭負荷越低外，端部包覆情況亦越差。藉由提高包材與模具間的摩擦，可降低褶料缺陷的產生，同時亦增加端部包覆的效果。此外，增加包材與芯材二端部間高度差，亦可提高包覆效果。

關鍵字

嵌埋式金屬複合塊材 ； 鋁合金 ； 鍛造 ； DEFORM

並列摘要

This study attempted to create a hot forging process making core-shell type metal composite part. As an example, a countersunk head rivet geometry is formed with a socket shaped shell aluminum 6061 filled with a core aluminum 7075 metal in a die within one stroke of the punch. To investigate the feasibility of the process proposed by this study, the bottom height of the shell metal, the distance between the top ends of the shell and the core metal, the forging temperature, and the frictional shear factor between the dies and the shell metal are set as the process parameter for this study. As a result, the bottom of the shell metal should be higher the shoulder of the die in order to avoid the folding failure appearing at the bottom side corner of the shell metal. The higher the forging temperature, the lower the punch force and the worse the top end of the shell metal encapsulated. By raising the friction between the die and the shell metal, the folding failure might be eliminated and the top end of the shell metal might be better encapsulated. Furthermore, Increasing the distance between the top ends of the shell and the core metal could enhance the top end of the shell metal encapsulated.

並列關鍵字

Core-Shell Type Metal Composite Bulk ； Aluminum Alloy ； Forging ； DEFORM