螺旋傘齒輪近淨形之溫間鍛造分析

Analysis of Near Net-Shape Helical Bevel Gear Forging

洪承昌(Cheng. Chang. Hung)

指導教授 ： 楊東昇

國立虎尾科技大學/工程學院/創意工程與精密科技研究所在職專班/碩士(2010年)

摘要

鍛造製程具有材料使用率高、成品精度佳、強度高、加工時間短、低成本、使用壽命長、易於大量生產之優點，極具產業應用上價值，若鍛造製程的參數設定能以方便的方法預先模擬，應能有效提高鍛造的實用性。本文以螺旋傘齒輪近淨形溫間鍛造為例，首先利用有限元素分析軟體來模擬螺旋傘齒輪的近淨形溫間鍛造過程，研究其不同過程參數下，如模數、齒數、模具溫度、胚料溫度等，探討最大成形負荷、最大等效應力、最大等效應變和最大齒輪溫度等之影響，以及胚料在模穴流動、變形情況及負荷值等，並製作模具進行實驗，對實驗值與有限元素分析軟體模擬值進行比較。最後，利用類神經網路建構螺旋傘齒輪近淨形鍛造的胚料體積與最大成形負荷的預測模式，以此兩預測模式進行預測，其結果比對有限元素分析結果相當良好。因此對於後續不同螺旋傘齒輪鍛造時，可先預測其最大成形力及胚料體積，再選用其所需之機台噸數及胚料體積，進而達到節省製程時間。

關鍵字

螺旋傘齒輪 ； 溫間鍛造 ； 有限元素分析 ； 類神經網路

並列摘要

There are several advantages of forging process, such as high yield ratio of material, good accuracy, high strength, short processing time, low cost, long lifetime and mass production. It is valuable in industry applications. If the parameters of the forging process can be simulated in advance, it should be able to effectively improve the practicality of forging. In this paper, the near net shape helical bevel gear warm forging is an example. First, a finite element analysis software is use to simulate the near net shape helical bevel gear warm forging process. To investigate the effects of process parameters such as modulus, number of teeth, temperature of die and temperature of workpiece on the maximum forging force, maximum effective stress, maximum effective strain and maximum gear temperature of near net-shape helical bevel gear. The flow of raw material in the die, DEFORMation and load value is analyzed by simulation, Then a die is made for experiment. Comparison between the results from simulation and experiment is carried out accordingly. Finally, the abductive network was then applied to synthesize the data sets obtained from the numerical simulation. The predicted results of the initial billet’s volume and maximum forging force of near net-shape helical bevel gear warm forging from the prediction model are consistent with the results obtained from FEM simulation quite well . Therefore, the maximum forming force and initial billet’s volume will be predicted when the differ helical bevel gear forging, then choice an amount of ton of machine and initial billet’s volume for saving the time of process.

並列關鍵字

helical bevel gear ； warm forging ； finite element analysis ； abductive network.

參考文獻

【35】許源泉，鍛造製程分析講義，國立虎尾科技大學機械製造工程系，雲林，臺灣。

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