- 學位論文
汽車底盤懸吊系統零件鍛造研究
Study on Forging of SSA Component Rear Top Mount Housing
摘要
由於石化能源過度使用造成全球暖化，尤其交通運輸工具造成的CO2排放更是佔有很高的比重， 京都議定書於1990年定下2008年至2012年減少排放8%二氧化碳的目標。因此各家車廠提出相當多的改善方式，其中利用鍛造特性增加金屬材質或鋁合金材質強度達到相同或更強的品質要求，間接的減少材料之始使用，達到汽車輕量化以及節省能源消耗即是最有效的方式之一。本論文為探討鋁合金AL6082汽車懸吊系統底盤件Rear top mount housing之複合鍛造成形，首先採用工研院GLEEBLE 3500機型壓縮試驗設備進行AL6082鋁料熱壓縮試驗，以四種不同溫度及五種不同應變率條件下完成真實應力-真實應變曲線參數供有限元素軟體Deform進行模擬分析。並依據分析過程與結果了解到模具設計過程中金屬的流動、機台的負荷、材料與模具之間的摩擦係數及工件與模具熱傳情況做為模具設計與修改的依據，以縮短開模的時程及降低的開模成本。 因本研究零件外型複雜無法僅以一般傳統2D鍛造方式成型，因此增加3D鍛造製程，藉由傳統上、下衝擊成型外還增加了兩側壓缸成形，此製程讓工件更趨於接近完成品的尺寸以提高得料率、減少加工製程時間以及增加工件機械性質。分析試驗結果顯示一般鍛造(2D鍛造)取得之參數為材料溫度540℃、模具溫度200℃、摩擦係數0.3，與三向鍛造(3D鍛造)取得的參數為材料溫度450℃、模具溫度250℃、摩擦係數0.3，經由以上條件進行實驗，其結果在2D鍛造及3D鍛造成形性及機械型質都符合預期
並列摘要
Overuse of fossil energy has resulted in global warming, and the major cause is the CO2 exhausted by motor vehicles, so that Kyoto protocol has set the target of 8% reduction of CO2 during 2008 to 2012. Since then, car manufacturers has presented many improvements, and one of the most effective methods for lightweight and energy saving is to produce parts by forging, thus higher mechanical properties and lighter weight of the metallic alloy parts can be reached. In this thesis, the compound forging of SSA part (Suspension System Architecture) rear top mount housing by using aluminums alloy AL6082 was studied. Firstly, thermal compression test on AL6082 was conducted by using GLEEBLE 3500 machine in ITRI, in which 4 different temperatures and 5 different strain rates were inter-tested. The true stress-strain curve was then obtained and input in DEFORM to conduct forming analysis, in which the metal forming condition, forging load, coefficient of friction between tooling and material, and heat transfer between part and tooling were studied. The results were provided to improve the tooling design and reduce the lead time and cost of tooling manufacture. The geometry of rear top mount housing in this study is very complex and cannot be forged by using conventional forging (uni-directional), so that three-way forging was introduced, in which the conventional top die and bottom die were used in mechanical press, and two additional lateral cylinders were added in the pressing. Thus, the shape of forged part was closer to the final product, so that the material yield rate was increased, machining cycle time was reduced, and higher mechanical properties were reached. The analysis results showed the processing parameters for conventional forging were: material temperature 540°C, die temperature 200°C, and frictional coefficient 0.3; In contrast, the processing parameters for three-way forging are: material temperature 450°C, die temperature 250°C, and frictional coefficient 0.3. Some experiments were conducted by using the parameters mentioned above, and the results showed both the conventional and three-way forging can reach the expected formability and mechanical properties.