汽車安全氣囊用筒形端蓋之沖壓製程分析

Stamping Process Analysis of the Cylindrical Cap Used in Automobile Air Bag

張文相(Wen-Hsiang Chang)

指導教授 ： 許源泉

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(2011年)

摘要

摘要
目前全球汽車生產量每年為六千三百萬輛，其中安全氣囊幾乎為目前汽車之標準配備，每年所需安全氣囊超過一億個，在全球代工體系下，台灣業者切入這一塊市場極具成本與技術優勢。本文採用有限元素分析軟體DEFORM-2D進行汽車安全氣囊用筒形端蓋之沖壓製程分析，針對各道次製程胚料的塑性流動變形、應力及應變分析以及各道次製程的成形力、模具應力及模具磨耗分析，最後對各道次製程設計模具結構及開發模具並組立試模，與模擬結果進行比較分析。
研究結果得知，沖壓件等效應變主要集中在筒形外緣端部，在整平鍛壓階段沖壓成形負荷最大，模具應力在整平鍛壓階段沖頭受等效應力最大，模具磨耗在引縮階段母模角隅磨耗最嚴重，而模擬與實驗製品件量測結果相當一致，差異值最大不超過8%，本研究結果證實有限元素分析可有效預測製品沖壓件成形過程、模具受力及磨耗狀態及成形件尺寸精度之控制。

關鍵詞：安全氣囊;沖壓製程分析;整平鍛壓;有限元素分析

關鍵字

安全氣囊 ； 沖壓製程分析 ； 整平鍛壓 ； 有限元素分析

並列摘要

Abstract
Now the global production of automobile is 63 million each year. Air bag is almost its standard accesory. The need for air bag is over 100 million yearly. Under global OEM system, Taiwan manufacturer has the cost and technical superiority to cut into this market. This finite element analysis software DEFORM-2D to proceed the stamping process analysis of the cylinder cap that used on air bag, according to plastic flowing deformity, stress and analysis of raw material in every process, and the forming power, tooling’s stress and wearing analysis in every process. At last, to compare every process’ tooling design structure, develop tooling and tooling’s trial with the simulating result.
From the research, stamping part’s effective stress mainly focuses on the outer tip of the cylinder. In the flattening and forging process, the staming has the biggest loading. Tooling’s stress in the flating and forging process, the punch has the biggest effective stress. The tooling’s wearing in the drawing process, the female die’s corner has the most serious wearing. The simulating and the test part have quite the same measure result, the difference is no more than 8%. This research has proved that finite element analysis can efficiently predict the stamping part’s forming process, tooling’s stress, wearing situation, and the control of the forming dimension’s precision.

Key words: Air bag; Stamping process analysis; Flattening and forging; Finite element analysis

並列關鍵字

Air bag ； Stamping process analysis ； Flattening and forging ； Finite element analysis

參考文獻

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