伺服運動曲線應用於汽車零件外殼之深引伸製程研究

The Analysis of Servo Motion Curve in Deep Drawing Prcess of Automotive Motor Casings

張宇良(Yu-Liang Chang)

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

本研究目的為利用伺服沖床找出較佳之伺服運動曲線以提高深引伸極限引伸比、減少成形道次及增加尺寸精度，首先進行傳統曲柄運動曲線對圓杯深引伸製程做設計探討，再藉由電腦輔助工程軟體模擬圓杯之深引伸製程，並依據不同的設計參數，如模具間隙、壓料力、模具圓角、摩擦係數及伺服運動曲線(如單次回復或多次回復運動曲線)等參數，對圓杯之變形、應力、應變分佈及破裂情形做分析，再配合現有設備以伺服曲線實際進行深引伸成形，驗證其模擬分析結果與實驗是否相符，其實驗結果發現伺服曲線引伸加工，在相同模具條件下加工不同直徑之胚料後，伺服曲線能順利引伸最大的胚料直徑，比傳統設計極限引伸比最大之胚料直徑加了6~8%。
最後將伺服運動曲線應用於汽車馬達外殼之深引伸產品，以伺服曲線最佳化參數設計模具，接著依設計進行汽車產品模具與製作，再將完成模具以不同伺服運動曲線(多次回復曲線)引伸加工，實際找出汽車馬達外殼產品的較佳伺服運動曲線，期能減少成形道次，並實際利用適合的伺服沖壓機進行深引伸成形，最後發現其胚料尺寸變化的均勻性與伺服運動曲線頻率多寡成正比。

關鍵字

伺服沖床 ； 深引伸 ； 極限引伸比 ； 多道次 ； 汽車馬達外殼

並列摘要

The purpose of this study was to identify the ideal servo motion curve of a servo press to increase the limiting drawing ratio (LDR), reduce the number of forming passes, and enhance the dimensional precision of the deep drawing process. First, a conventional crank motion curve was applied to design and explore the deep drawing process for circular cups. Then, a computer-aided engineering (CAE) software was used to simulate the same deep drawing process. Different design parameters, such as die clearance, press force, die corner, friction coefficient, and servo motion curve (e.g., single recovery and multiple recovery of motion curves) were applied to analyze the deformation, stress/strain distribution, and fracture/cracking of the circular cups. Using available equipment, the servo curve was applied to physically implement the deep drawing process and verify whether the analysis results were consistent with the experiment outcomes. The experiment outcomes revealed that under the same die conditions, the largest blanks the drawing process could process using the servo curve was 6% to 8% larger in diameter than drawing processes using a conventionally designed LDR.
Moreover, the servo motion curve was applied to the deep drawing of automotive motor casings. The optimal parameters of the servo curve were applied to design and fabricate the die for the automotive product. It was then used in a drawing process coupled with different servo motion curves (multiple recovery of motion curves) to identify the optimal servo motion curve for drawing automotive motor casings. Using the optimal servo motion cure in deep drawing processes can effectively reduce forming passes and ensure that a suitable servo press is employed in deep drawing. Finally, the findings of this study revealed the uniformity in the size variance of blanks was significantly and positively correlated with the frequency of the servo motion curves.

並列關鍵字

Servo Presses ； Deep Drawing ； Limit Drawing Ratio ； Multistage ； Car Motor Shell

參考文獻

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