精密齒型衝剪加工之製程參數研究

Study on the Operating Parameters of Fine Gear Blanking Process

阮翔瑜(Xhian-Yu Juan)

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(2008年)

https://doi.org/10.6841/NTUT.2008.00600

摘要

在許多金屬切削加工中，衝剪下料為效率最快且能夠大量生產的加工方法，其中精密衝剪可以使成品的製作更微小化，並且精度能夠相對提高，然而衝壓製品的品質關鍵往往決定於衝壓製程的操作參數，因此本論文將對於特定齒型的精密衝剪製品，先利用有限元素分析模擬衝剪過程的狀態，以了解衝剪荷重與衝壓行程的關係、精密齒型的成形情況與特徵齒型斷面的應力應變分佈情況，並探討加工條件之間的關係。實驗方面，利用田口式品質設計方法對於精密衝剪加工機的四種操作參數（上模壓力、衝壓行程、下模壓力、材料性質），進行參數設計實驗，以尋找在不同的品質目標的定義下最好的加工參數組合，實驗結果顯示，在不同的齒型部位有不同的最佳化參數組合，在齒頂面的剪斷面品質提升需要使用較小的上模壓力；在齒型輪廓的精度提升需要使用較大的下模壓力，在中碳鋼、鋁合金和黃銅三種材料中以黃銅能夠衝剪出較佳的剪斷面品質。

關鍵字

精密衝剪 ； 有限元素法 ； 田口式品質設計方法

並列摘要

Blanking process is one of the fastest and effective method for mass production of sheet metal parts. And fine blanking technology has the features for the manufacture of high precision small parts. However, the quality of product processed by fine blanking largely depends on the operating parameters used. Therefore, the purpose of this paper is to study the optimal operating parameters that can be used in the production of small gear shape sheet metal product. First, Finite Element method is used to simulate the whole blanking process and to informate like cutting force versus stroke relation, the stress-strain distribute of blanking parts are expand on review. Next, Taguchi quality design method is used to find the optimal parameters of experimental press used for fine blanking of gear shape sheet metal parts. The four control parameters used in this study are punch pressure, stroke of punch, counter punch pressure, and materials. The experimental result show that counter punch pressure has efficacious effect on the contouring accuracy of gear tooth property. And the quality of gear tooth made from brass seems to be better than those from carbon steels and aluminum alloy.

並列關鍵字

Fine blanking ； Finite element analysis ； Taguchi quality design method

參考文獻

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