- 學位論文
最佳實驗設計與DEFORM分析在內六角螺栓頭成形之應用
Best experimental design with DEFORM analysis Application of Hexagon Socket Head
摘要
鍛造(Forging)是藉著衝擊或擠壓的方式將材料進行塑性變形一種加工，成形後材料組織較為細密、晶粒流動連續而有良好的機械性質。但其製程技術及變數多，尤其是在新開發零件模具與胚料的設計，經常造成材料的未充填、包料及溢料的現象，進而影響產品開發時程及成本。 有鑑於此，本論文擬以DEFORM有限元素分析軟體及Design Expert最佳化分析軟體進行鍛造製程的研究，文中分成兩部分進行：一是以DEFORM有限元素分析軟體進行新產品的模具及胚料設計之參數模擬及實際鍛打驗證；二是以最佳化分析軟體Design Expert針對內六角螺栓頭成形之合模線、體積分配及溫度等鍛造製程參數及因子進行模擬實驗設計，以DEFORM進行模擬已得到不同參數設計的實驗數據，再輸入到Design Expert進行鍛造參數的最佳化設計。 本研究結果得知：(一) DEFORM模擬鍛造成形分析中正確預測金屬材料的填充不足及疊料等缺陷之位置，並能預先修正模具及相關參數之設計，達到快速開模並減少試模次數與修改模具時效與失敗風險，促進產業競爭能力；(二)此一方式可供鍛造界業者在進行從事鋁合金相關鍛造零件之開發時做為一種選擇參考。
並列摘要
Forging processing is the way through the impact or extrusion, the forging from a shape to the plastic deformation of the method into another shape, Which does not change the quality of the workpiece and its material composition, in order to achieve the required shape and mechanical properties. Forged products due to forging or extrusion of the plastic forming method, so the material is more fine, and the grain flow continuous, leaving the material has good mechanical properties, it is suitable for mass production process, can directly save material costs. Due to forging a lot of process variables, and the required technology and experience are not a short time to accumulate the establishment, it is not easy to master, directly affect the process, the results of control and effectiveness. In recent years, the relevant researchers engaged in forging processing for the shortcomings of forging processing, put forward a lot of solutions, and strive to improve, which in the hardware equipment to automate the forging production line and rapid mold change and so on to reduce the manual demand and improve product quality and product Stability, and in the software equipment to CAE, CAD, CAM to help process the design to respond to a variety of products, a small amount of production trends, the rapid response to market demand requirements. In this paper, the results of DEFORM finite element analysis software are used to simulate the results. The design parameters are designed according to the parameters and factors of the forging process to reduce the number of simulations and then enter the different forging parameters Optimized design of experimental data. In this study, the parameters such as mold line, mold R angle, volume distribution and temperature were used as experimental factors. From the DEFORM simulation forging and forming analysis, it was predicted that the forming and filling of metal materials in the forming process In order to understand the aluminum alloy 6061 parts in the hot forging process in the form of changes in the impact, and can pre-modify the mold design parameters, to achieve rapid mold and reduce the number of test mode and modify the mold aging and failure risk, improve forging mold development capabilities and savings Development time and cost-effectiveness, and promote industrial competitiveness. This method can be used as a reference for the forging industry to carry out the development of aluminum alloy related forged parts