輥軋成形技術應用於製管製程之研究

The Study of Roll Forming Technology Applied to Tube Manufacturing Process

林信良(Lin, Sin-Liang) ； 曾俊傑(Zeng, Jun-Jie) ； 陳復國(Chen, Fuh-Kuo)

《鍛造》 26卷2期 (2017/07) Pp. 8-14

摘要

近年來輕量化以及高強度已成為汽車產業發展的主要趨勢，為達成此目標汽車業已廣泛使用管件液壓成形技術取代傳統沖壓技術，然管件液壓成形技術為複雜多樣式的成形道次，需要很大的伸長量來進行變形，因此常會有破裂缺陷的產生，而製管製程不佳，導致偏移應變過大是造成此缺陷的主因之一。本研究因此針對製管製程的問題進行研究，藉由電腦輔助工程分析（Computer Aided Engineering, CAE），以實際之輥輪配置，並使用先進高強度鋼（Advanced High Strength Steel, AHSS）為材料，進行輥軋成形製管製程之研究，並建立輥軋成形之模擬分析技術。本研究建立輥軋成形之模擬分析模型後，並針對管材厚度以及軸向拉伸應變進行比對，得知該分析模型之精度達93%。後續將可利用此分析模型進行各製管參數對於製管成形與偏移應變之影響分析，改善製管製程偏移應變過大的問題，進而改善後續管件液壓成形容易產生破裂缺陷之問題。

並列摘要

In order to achieve the design goal of high strength and light-weight, the tube-hydroforming technology has been widely applied to the manufacturing process for automotive structure parts. The tube-hydroforming technology consists of complicated multi-operations. The localized expansion always produces large deformation and is apt to causing fracture defect. In order to cope with this dilemma, the off-set strain of sheet metal produced in the tube manufacturing process is expected to be as small as possible. In the present study, the effects of the process parameters on the off-set strain produced in the tube manufacturing process were investigated by the finite element analysis. An existing roll-forming set-up was adopted in the finite element model and the 780MPa advanced high strength steel(AHSS) sheet was used to make the tube. The software PAM_STAMP 2G was employed to construct the finite element model for the roll-forming process and to simulate the tube manufacturing process. In this study, the simulation analysis model of roll forming is established, and the accuracy of the analysis model is 93% according to the comparison of tube thickness and axial tensile strain. The analytical model can be used to analyze the effect of various process parameters on the tube forming and offset strain, and to improve the problem of excessive deflection of the tube manufacturing process, and to improve the fracture phenomenon in the tube hydroforming.