管件液壓製程設計優化之研究

A Study on Process Design Optimization of Tube-Hydroforming

王辰瑋(Chen-Wei Wang)

指導教授 ： 陳復國

國立臺灣大學/工學院/機械工程學研究所/碩士(2020年)

https://doi.org/10.6342/NTU202002571

摘要

隨著節能減碳等綠能環保議題日益受到重視，低油耗與輕量化為汽車產業之發產趨勢。管件液壓成形之成品有著重量輕、強度高、製程簡單、節省材料等優點，其技術已被大量應用於汽車零組件與結構件之中，而利用電腦輔助工程(Computer Aided Engineering，簡稱CAE)評估成品成形性已成為管件液壓成形技術中重要的一環。然而，依照一般的管件液壓成形CAE模擬之分析流程進行分析，在成形性不夠理想的情況下時常需要對製程與模具進行修改並重新進行模擬分析，此時將增加製程設計所耗費的時間。
本論文針對管件液壓成形之製程設計進行討論，並對各製程之應用進行分析，探討成品造型對製程設計之影響，最後對管件液壓CAE模擬分析流程進行修改，以降低CAE模擬分析所需之時間與提高製程設計之準確性為目標。利用有限元素法軟體分析，以實際案例探討製程之應用與模具之優化。
本論文對預成形進行介紹，並針對製程之應用進行探討，分析造型對製程設計之影響。在模具優化方面，本論文利用CAE對模具優化前後之模擬結果進行比對，評估模具優化成品之影響。在模擬分析流程優化方面，本論文利用造型分析減少模擬分析之時間，並整理製程之應用。本論文利用模具之優化減少所需之控制機台，並以實際案例將有限元素法軟體之模擬結果與實際成品進行比較，驗證有限元素法之準確性。
本論文研究成果改善了管件液壓之模擬分析流程、整理製程與模具設計相關之應用，給予管件液壓成形相關之製程設計、模具開發人員參考。

關鍵字

管件液壓成形 ； 製程設計 ； 預成形 ； 有限元素法

並列摘要

As carbon reduction and some green energy environmental issues are considered as an important issue increasingly, low fuel consumption and lightweight of car body are the major development trends of the automotive industry. The product of tube hydroforming has the advantages of light weight, high strength, simple manufacturing process, and material saving. Thus, tube-hydroforming technology has been widely used in automobile components and structural parts. And using CAE to evaluate the formability has become an important part of tube-hydroforming technology. However, according to general analysis process of the tube-hydroforming CAE simulation analysis, if the formability is not ideal, the process and die must be modified and the CAE simulation must be re-simulated. This will increase the time spend on process design.
This thesis first discusses the process design of tube-hydroforming, analyzes the application of each process, studies the impact of modeling on process design, and finally modifies the CAE simulation analysis process. The goal of this thesis is to reduce the time required for CAE simulation analysis and improve the accuracy of process design.
This thesis uses finite element method software for analysis and uses actual cases as examples to search the application of the manufacturing process and die improvement.
This thesis introduces pre-forming, discusses the application of the process, and analyzes the impact of modeling on the process design. In terms of die improvement, this thesis uses CAE simulation to compare the simulation results before and after die improvement and evaluate the impact die improvement on products. In terms of the improvement of the simulation analysis process, this thesis uses modeling analysis to reduce the time of simulation analysis and to organize the application of the process. This thesis modifies the die to reduce the control machines, and compares the simulation results of the finite element method software with actual products in actual cases to verify the accuracy of the finite element method.
The research results of this thesis improve the simulation analysis process of tube-hydroforming, sort out the process and the application of die design, and give reference to process design and die developers related to tube-hydroforming.

並列關鍵字

tube-hydroforming ； process design ； pre-forming ； finite element method

參考文獻

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