不鏽鋼圓杯引伸製程參數之研究

Study on the Process Parameters in Deep Drawing of Stainless Circular Cups

施榮佳(Jung-Chia Shih)

指導教授 ： 陳政順

國立臺北科技大學/機電學院/製造科技研究所/碩士(2009年)

摘要

鈑金件引伸成形時之各個製程參數對金屬鈑的成形作用與最終產品品質有著很大的影響，所以本文首先利用有限元素法與田口實驗法找出不鏽鋼304圓杯引伸成形製程參數的貢獻率，最後再針對貢獻率較高的前三個重要因子再行實驗設計與分析，探討各個因子參數對整個製程的影響程度。在引伸成形分析中，材料模式使用指數定律方程式 (Power law Plasticity)，接著利用田口實驗法中的L18直交表，主要的控制因子有壓料板與下模穴之間隙、沖頭與下模穴之間隙、下模半徑(Rd)、沖頭速度、摩擦係數、胚料壓料力、沖頭肩半徑(Rp)、胚料大小等因子進行18組分析實驗，並以胚料厚薄率越小為其實驗目標，所以使用田口實驗法之望小特性的品質分析法，經由田口實驗法中品質特性因子反應表以及S/N比折線圖與反應表，初步研究結果顯示影響圓杯引伸成形中最大的三個因子，分別是胚料大小(22.4%)、沖頭與下模穴之間隙(11.3%)、胚料壓料力(9.8%)等三個因子。接者再利用直交表L9進行參數設計實驗，以尋找在不同的目標定義下最大的影響因子，F檢定結果顯示，在整體部位的厚度減少率品質的提升需要改變胚料大小；在杯底面部位的厚度減少率品質的提升需要改變沖頭速度。

關鍵字

引伸成形 ； 有限元素法 ； 田口方法 ； 圓杯引伸

並列摘要

Forming parameters in deep drawing of various sheet metal parts have a great influence on the final product quality. In this study, the finite element method and Taguchi method are used to investigate the process parameters effects on the drawing of 304 stainless circular cup. The formula of Power law Plasticity is used to described the material model. Experimental procedure consist of using L18 orthogonal array, calculate S/N ratios, linear graphs and factor response graphs. The eight process parameters proposed in this study are the gap between punch and die, the gap between blank holder and die, die radius, punch speed, friction coefficient, blank holder force, and punch radius, blank size. The objectives of experimented study is the smaller the rate of change of thickness, that is the analysis for quality is Smaller-the-Better. The result of study shows that the first three parameters contributed the forming product quality are blank size(22.4%), die radius(11.3%), and blank holder force(9.8%). A further study has also been down to evaluate the significance of these three control parameters, through L9 orthogonal array and F distribute check. The result show that thee blank size significance influence on the quality of whole cups and the pure speed has very significance effect on the quality of botton of cup.

並列關鍵字

Deep drawing ； Finite element method ； Taguchi method ； drawing of circular cup

參考文獻

[11] 阮祥瑜，精密齒型衝剪加工之製程參數研究，碩士論文，台北科技大學製造科技研究所，台北，2008。

[15] 姜禮銀、邱年鴻，模具學(一)，台北：科友圖書股份有限公司，1997，第215-218頁。

[1] D. M. Woo, "The Stretching Forming Test, "The Engineer, Vol.200, 1965, pp. 876-880.

[2] D. M. Woo, "On The Complete Solution of The Deep-drawing Problem, "Int. J. Mech. Sci. Vol. 10, 1968, pp. 83-94.

[3] R. Padmanabhan, M.C. Oliveira, J.L. Alves, L.F. Menezes, "Influence of process parameters on the deep drawing of stainless steel, "Finite Elements in Analysis and Design, Vol.43, 2007, pp.1062 - 1067.