皮帶輪近淨形之伺服鍛造技術與模具開發

Servo Near Net Forging Technology and Mold Development of The Pulley

王鈞(Chun Wang)

指導教授 ： 楊東昇

國立虎尾科技大學/工程學院/機械與電腦輔助工程系碩士班/碩士(2017年)

摘要

本論文研究係針對AISI-1010低碳鋼皮帶輪零件，利用有限元素法之金屬成形模擬軟體DEFORM 3D進行低碳鋼皮帶輪近淨形鍛造製程的模擬分析與鍛造模具設計，並結合伺服沖床上的伺服曲線技術應用於皮帶輪齒形鍛造成形，首先模擬皮帶輪預成形鍛件與近淨形鍛件之冷鍛過程，在不同預成形圓角、預成形斜角的參數下，得到預成形鍛件最佳化設計，分析近淨形鍛造的最大成形力、最大等效應力、胚料體積之影響，並模擬脈波伺服曲線與持壓伺服曲線應用於皮帶輪齒形鍛造成形，並與傳統曲線鍛造成形比較，其鍛件其最大成形力、鍛件最大等效應力、齒形沖頭最大等效應力，由模擬結果顯示使用持壓伺服曲線的鍛件等效應力比傳統曲線來的均勻，脈波伺服曲線下的鍛件等效應力分布最差；脈波伺服曲線應用於鍛造下的鍛件最大成形力、沖頭最大等效應力小於傳統曲線，進而延長沖頭模具壽命。本研究利用金屬成形分析軟體鍛造成形分析來進行鍛造模具的設計開發，決定模具尺寸及製程道次與參數後，製作出模具且實際進行鍛造實驗得到成品，最後為量測成品尺寸並確定是否符合產品設計之尺寸。

關鍵字

伺服鍛造 ； 近淨形鍛造 ； 皮帶輪 ； 有限元素分析

並列摘要

Aimed at AISI-1010 low carbon steel pulley components, a finite element method-based metal forming simulation software of DEFORM 3D was used to simulate and analyze the near net forging process for the low carbon steel pulley, and to design forging molds.This technology was used in the pulley tooth forging in conjunction with the servo press-based servo motion curve technology. First, the cold forging process of the pulley preform forging and the near net forging were simulated. The parameters of different preformed fillets and preformed bevels were investigated to obtain the optimal design for the preform forging, where the influence of the maximum forming force, the maximum equivalent stress, and the volume of the embryo material in the near net forging process was analyzed. Also, the applications of the pulse wave servo motion curve and the holding pressure servo motion curve in the pulley tooth forging were simulated, which were compared with the traditional motion curve-based forging forming, where the comparisons focused on the maximum forming force and maximum equivalent stress of the forged piece as well as the maximum equivalent stress of the toothed punch. The results indicated that equivalent stress caused by the holding pressure servo motion was more evenly than caused by the traditional curve, that the pulse wave servo motion caused the worst equivalent stress distribution, and that the maximum forming force of the forged piece and the maximum equivalent stress of the punch caused by the pulse wave servo motion curve were smaller than caused by the traditional motion curve. With this, the service life of the punch die was extended. In this study, a metal forming simulation software was employed to analyze the forging forming, whereby a forging die was developed and designed. After determining the die size, process pass and other parameters, we made a die, with which the finished products were forged experimentally. Finally the product size was measured to verify whether it met the design requirement.

並列關鍵字

servo forging ； near net forging ； pulley ； finite element analysis

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