- 學位論文
微形手術刀之鍛造成形製程分析與改善
An Analysis and Improvement of Forging Processes for Micro-Scalpels
摘要
台灣鍛造產業歷史悠久，多數鍛造產品都是以冷鍛方式加工產生，目前業界最大問題在於，技術多仰賴師傅傳承，及反覆測試，相當耗費工時與成本，更因為人為因素，導致經驗無法傳承，使得好不容易取得的經驗，就這樣消失了。本文透過實物試驗配合電腦輔助模擬分析進行驗證，讓加工製程能更進一步的提升。 本論文研究探討微形手術刀鍛造製程設計與分析，針對目前加工製程進行改善，達到縮短加工製程時間及節省加工成本。本文分為實物試驗與數值模擬分析，實驗得到微形手術刀鍛造成品，再利用Deform-3D分析軟體模擬出的結果與產品外形進行比對，確認無誤後。再使用Deform-3D針對微形手術刀鍛造製程分析與改善。 模擬分析分為三道次，每道次所產生的胚料流動變形，應力，應變分佈狀況及模具產生之應力，磨耗等狀況，進行討論與研究。從模擬結果得知，第一道次成形外形變化最小，其次為第三道次，第二道次外形變化最大，第一道次最大應力發生在刀頭內部，第二道次與第三道次則發生在刀頭外側周圍。模具最大應力為第二道次，其次為第三道次，最後則是第一道次。 模擬分析結果與實驗比對，模擬分析所得到的數據與成品尺寸差異不大，都在圖面公差±0.05內，顯示模擬後所得到的數值，參考價值極高，往後可作為開發設計的參考依據。得到一套符合目前鍛造的加工模式，達到縮短加工製程時間及節省加工成本的目的。
並列摘要
Taiwan forging industry has a long-standing history. Most of forged products are manufactured through cold-forging technology. Currently, the industry biggest challenge is how to pass on the knowledge base. The forging knowledge and skills still mainly rely on the master-teaching and the repetitive-testing, all of which are time and cost-consuming. And due to human factors, this hard-earned knowledge and skills could be disappeared when the experience can’t be passed on. This dissertation is to explore and improve the forging process through product testing incorporating the computer-aided simulation analysis to conduct verification. The dissertation is to research the forging process and analysis on minimally invasive surgical knife and to improve the process in order to shorten the manufacturing time and save the costs. The paper will compare the product prototype and data simulation through computer. The forged prototypes of the minimally invasive surgical knife from experiment will be used to compare with the simulation result from DEFORM-3D software in terms of product contour. After confirmation, Deform-3D will be used to analyze the forging process and provide improvement. Simulation analysis is a 3-step forming process. And each simulation and parameters that deformed of material, load, stress, strain distribution and die stress, wearing condition is discussed and researched. According to the simulation result, we learned the first step of forming process had the least variation of shrinkage. Then, the third step. The second step had the most variation of shrinkage. The maximum stress of the first step occurred at the inside of knife tip; whereas for the second and the third step, it occurred at the outside of knife tip. The maximum mold stress is the second step, followed by the third step, and the last is the first step. Based on the comparison of simulation analysis and actual product, there is little variation between the data gathered from simulation and actual dimension of product. The simulation can controlled the tolerance within +/-.5. Therefore, the computer-aided simulation analysis can be use as the reference when developing and designing a forging die which is optimized the current forging process to shorten the time and save the costs.