近直角IC零件沖壓變形行為分析及實驗驗證

近年電子零件往輕薄短小的設計，許多沖壓零件的成形需求也隨之提高，本文即探討小的電子零件於轉角處必須達到近乎直角之下的製造及分析過程，由於直角的彎折會產生皺摺、扭曲，因此達成形狀尺寸的難度相當高。本文應用Dynaform5.9.3分析及實驗驗證，分別探討摩擦係數、沖頭間隙及胚料轉角輪廓對形成直角的影響，並找出可行的設計方案，另外本文以動態拉力試驗機測試於平面引伸成形過程，尖角處對於破裂的影響程度，實驗分析顯示，在沖壓的過程中，尖角處往往是最早達到破裂強度的部位。就結果而言，近直角部位的皺摺變形無法藉由調整摩擦係數及沖頭間隙而達到符合尺寸要求，改以調整胚料轉角區胚料形狀，經過測試T5形狀的曲線設計最接近成品設計的需求。另外應用動態拉力試驗機測試尖角效應，無論是硬度240HV或是硬度180HV的不鏽鋼材料，皆證明在尖角處的應力及厚度變化最大，最易產生破裂狀態。

關鍵字

模具；沖壓； Dynaform ；動態拉力試驗機

並列摘要

Recently years, the size of 3C metal electric components are getting smaller and smaller, which result in increase of the forming complexity. This research is to analysis how to manufacture small 3C component with right angle at corner. Due to bending with right angle will cause wrinkled、twist, therefore it’s quite difficult to eliminate the defect while forming part and meet customer dimension requirement. This research apply Dynaform to simulate how the parameter of fraction, punch and blank corner profile affect to the forming of right angle and to find out the best parameter. Besides, this research also using Material testing system(MTS) machine to do actual practice for flat blank material to do drawing process. Both simulation and test shows that the sharp corner is the earliest reach to crack. According to the result, defect of wrinkled、twist closed to the right angle bending area is unable to achieve dimension requirement by adjust the fraction and punch gap. But if turns to adjust the blank corner area shape, after five times simulate and practice, the result will closest to requirement. This research also take MTS machine to practice for sharp corner effect. No matter stainless steel hardness is 240 or 180 HV, both conditions are verified that the biggest variation of stress and thickness happened at sharp corner area, and caused crack.