薄殼鋁合金管件縮頸旋壓製程分析

Analysis of the Neck-in Spinning Process of Thin Aluminum Alloy Tubes

許正杰(Cheng-Jie Hsu)

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(2010年)

摘要

本研究採用三維彈塑性有限元素分析技術進行內肋旋壓製程之成形過程模擬，探討鋁合金薄殼管件縮頸內肋旋壓過程中變形應力及應變的分佈規律，藉以瞭解其對縮頸內肋製程、模具及製品的影響。研究結果顯示，在本個案當型模支撐間距為50mm時，比較型模支撐間距為40mm、60mm，更容易得出所需的肋厚高度，並將有限元素分析所得參數與加工試驗試片相比較，證明有限元素模擬之可行性。接著利用田口實驗法中的 直交表，主要的控制因子有支撐間距、型模轉速、進給速度和輥輪直徑等四個因子，每ㄧ因子各有3個水準，進行9組分析模擬實驗，並以旋胚成形肋厚值5mm為其實驗目標，即使用田口實驗法之望目特性的品質分析法，經由田口法中品質特性因子反應表以及 S/N 比折線圖與反應表，顯示出影響縮頸旋形中最大的兩個因子，分別是進給速度(15.35 %)和支撐間距(4.43%)。

關鍵字

縮頸旋壓 ； 有限元素分析 ； 田口法

並列摘要

This investigation has adopted three-dimensional elastic-plastic finite element numerical simulation technology to perform the inner rib forming analysis, discuss the distribution of stress & strain during the neck-in inner rib spinning, thus to study the effect of these neck-in inner rib, mould, and product, by a different parameters of forming. As the analysis result shown, while the supporting distance of spinning mold have become 50mm, has deformed permanently to have a better height of rib in comparison with 40mm, and 60mm; and to compare the manufacturing experiment with this optimal value from the analysis of finite element, thus proving the possibility of this finite element simulation. Then use the orthogonal array from Taguchi method, including 4 main control factors which are the supporting distance of mold, rotation speed of mold, feed rate, and roller diameter, each of them separately have 3 levels, undertaking 9 sets of analytical simulation experiments, also take the experimental goal to be 5mm blank rib thickness, so use the Taguchi quality design method of nominal the best within the orthogonal array. In this case study, the result form the calculate S/N ratios, linear graphs and response graphs of control factors display two of the biggest factors that affects neck-in spinning , they are separately 15.35 % of feed rate and 4.43% of supporting distance of mold.

並列關鍵字

Neck-in Spinning ； Finite Element Method ； Taguchi method

參考文獻

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