- 學位論文
彎管製程特性對管件液壓成形性之影響研究
A Study of the Effect of Tube-Bending Performance on the Tube-Hydroforming Formability
摘要
汽車產業近年發展趨勢為輕量化以及高強度，汽車業界已廣泛使用管件液壓成形技術取代傳統沖壓技術，通常管件液壓成形道次為：彎管、預成形、液壓成形。本論文針對彎管製程中芯球對彎管成形及液壓成形之影響進行研究，並針對其做優化與改善。 本論文首先建立CAE彎管製程道次之分析流程與分析參數，並針對彎管幾何參數、製程參數、芯球參數以及材料參數進行探討，了解各參數對彎管成形之影響程度，針對彎管製程管材會有破裂、不飽滿等缺陷進行量化，完成統整數據並比較彎管成形及後續液壓成形性的影響探討。 在了解彎管成形後，本論文進行彎管製程對液壓製程的影響性說明。首先，探討彎管模擬的必要性，討論彎管模擬分析與有限元素法PAM-STAMP內建STB模組之差異性，並驗證得在液壓成形模擬時加入彎管模擬分析結果的準確性較高。在確立彎管模擬的必要性後，由於最能影響彎管截面變化的便是芯球的添加，因此探討彎管模擬中芯球使用的時機，以膨脹率和截面形狀入手，討論出最佳使用時機。由於液壓件之彎管成形並不是最終產品，所以不需要有最完美之截面形狀，而是要有利於後續的液壓製程，因此在參數設定上可做調整，透過芯球參數、管材幾何參數等進行探討，並優化液壓結果。藉由本論文之研究成果建立彎管製程管件的機台參數及芯球參數之選擇，並對需要液壓之管件在彎管製程時，有判斷芯球使用與否的通則，並對芯球參數、管材幾何參數選擇做一整理。
並列摘要
In recent years, the development trend in the automotive industry is light weight and high strength. The automotive industry has widely used tube hydroforming technology to replace traditional stamping technology. Generally, a tube hydroforming process includes tube bending, pre-forming and hydroforming. This thesis focuses on the research of tube bending technology in the tube bending process and the tube-hydroforming process. First, the analytical procedures and the analytical parameters of the manufacturing processes of CAE were established. The geometric parameters of tube, process parameters, parameters of mandrel ball and material parameters were also explored to understand the degree of impact of each parameter in the tube bending process. This thesis focuses on the defects such as cracking and cross-section not fully filled in the tube bending process. In order to integrate the data to compare the formability of tube bending and subsequent hydroforming, these defects must be quantified. After understanding the tube bending process, this thesis describes the influence of the tube bending process on the tube hydroforming process. The necessity of tube bending will be discussed, the analysis of the bending model and the differences by utilizing finite element method which uses PAM-STAMP for built-in simplified tube bending model were also explored. It was proposed that the hydroforming model with bending simulation resulted will be more accurate. After establishing the necessity of tube bending simulation, it is the addition of the mandrel balls that affect the cross-sectional change the most. Therefore, the next discussion will be the timing of using the mandrel balls in the simulation of the tube bending. Starting with the expansion rate and the cross-section shape, we discuss the best timing of using mandrel balls. Since the tube bending of hydroforming parts is not the final product, it does not need to have the perfect cross-section shape, but it has to facilitate the hydroforming process. It can be adjusted through the parameters of mandrel ball and bending curve, etc. Through the research results of this thesis, the selection of the tube bending machine parameters and mandrel ball parameters of the tube bending process is established. Moreover, the tubes which require tube hydroforming, there is a general rule for deciding whether the mandrel ball should be used or not furthermore arrange the selection of bending curve parameters and the mandrel ball parameters.
參考文獻
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