直齒傘齒輪近淨形之溫間鍛造分析

Analysis of Near Net-Shape Straight-Toothed Bevel Gear Warm Forging

賴力弘(Lee-Hung LAI)

指導教授 ： 楊東昇

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(2010年)

摘要

齒輪在各類機械中應用極為廣泛的重要傳動零件，以鍛造技術生產傘形齒輪具有節省材料、成品精度佳、成本低、效率高、易於大量生產及機械性質佳等優點，極具產業應用上之價值。若鍛造製程的參數設定能以方便的方法預先模擬，應能有效提高鍛造的實用性。本文採用三維剛塑性有限元素數值模擬技術進行直齒傘形齒鍛造塑性成形分析，首先利用有限元素分析軟體來模擬直齒傘齒輪的近淨形溫間鍛造過程，在不同參數下，如模數及齒數等，分析近淨形鍛造最大等效應力、胚料體積、最大成形力之影響，以及胚料在模穴之流動、變形情況及負荷值等，並製作模具進行實驗，對實驗值與有限元素分析軟體之模擬值進行比較。並利用類神經網路建構直齒傘齒輪近淨形鍛造的胚料體積、最大成形溫度與所需最大成形力的預測模式，以此預測模式進行預測，其結果比對有限元素分析結果相當良好。因此對於後續不同直齒傘齒輪鍛造時，可先預測其最大成形力及胚料體積，再選用其所需之機台噸數及胚料體積，進而達到節省製程時間。

關鍵字

直齒傘齒輪 ； 近淨形鍛造 ； 有限元素分析 ； 類神經網路

並列摘要

Gear is an important component or part used in mechanical system to transmit power. Bevel gear produced by forging possesses the advantages of material reduction, good accuracy,lower cost,higher efficiency , mass production and better mechanical properties . It is valuable in industry applications .If the parameters of the forging process can be simulated in advance, it should be able to effectively improve the practicality of forging.In this paper, the 3D rigid-plastic finite element simulation technique was used to analyze the plastic forming of Straight toothed bevel gear.First, a finite element analysis software is use to simulate the near net shape warm forging process for the Straight toothed bevel gear .Under different parameters, such as module, number of teeth, etc. The effect on the maximum equivalent stress, the volume of near net shape forging raw material, the maximum forming force, the flow of raw material in the die, deformation and load value is analyzed by simulation, Then a die is made for experiment. Comparison between the results from simulation and experiment is carried out accordingly. The abductive network was then applied to synthesize the data sets obtained from the numerical simulation. The predicted results of the initial billet’s volume and the maximum forming temperature and maximum forging force of near net-shape Straight-Toothed bevel gear warm forging from the prediction model are consistent with the results obtained from FEM simulation quite well . Therefore, the maximum forming force and initial billet’s volume will be predicted when the differ Straight-Toothed bevel gear forging, then choice an amount of ton of machine and initial billet’s volume for saving the time of process.

並列關鍵字

Straight -Toothed bevel gear ； Near net-shape forging ； Finite element analysis ； Neural network

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