鋁合金5052擠壓扣接製程有限元素分析

Finite Element Analysis of AA5052 Clinching Process

何坤峰(KUN-FENG HO)

指導教授 ： 林派臣

國立中正大學/工學院/機械工程學系/碩士(2016年)

摘要

本文是透過實驗及數值方法對擠壓扣接製程進行分析及模擬。第一部份工作是參考擠壓扣接製程的原理，開發等效實驗平台，並利用不同尺寸之沖頭、底板模具與試片進行測試及觀察。測試時，透過數位影像相關法(Digital Image Correlation)，量測扣件表面的應變分布狀況。另外，取得不同條件下的試片金相圖，量測扣件的幾何尺寸。最後，建立等效實驗平台之有限元素模型，模擬扣件的應變分布及尺寸變化，再與DIC量測結果與金相顯微圖進行比對，完成模型的驗證。第二部份工作是建立圓型擠壓扣接製程之有限元素模型，再配合扣件金相圖，完成模型的驗證。接著，利用此模型，進行模具尺寸對扣件形鎖尺寸(interlock)、沖頭下壓力(force)、扣件頸部寬度(neck)的效應分析，確認各尺寸的效應，並找出合適的新模具尺寸。最後，建立新模具的有限元素模型及實體成品，完成模擬與實體扣件的比對，確認擠壓扣接製程模型的準確度。

關鍵字

擠壓扣件 ； 數位影像處理法 ； 有限元素分析 ； 超彈性體

並列摘要

This paper presented analysis and simulation of the clinching process through experimental and numerical methods. The first part was to develop an equivalent experimental platform referring the concept of clinching, and then use different sizes of punches, molds and plates for testing and observation. During testing the strain distribution was measured from the surface of clinch joints using Digital Image Correlation. In addition, micrographs of clinch joints made under different conditions were measured to obtain their geometry. Finally, a finite element model of the equivalent experimental platform was developed to simulate the strain distribution and dimensional change of clinch joints. The numerical results were then compared with experimental results from DIC and metallographic micrographs to complete the verification of our finite element model.
The second part was to develop a finite element model of the circular clinching process and then complete the verification of the model by using the micrographs of clinch joints. Next, with the help of the verified model, the effects of each clinch mold dimension on the interlock, punching force, neck width of clinch joints were investigated and confirmed. Then appropriate clinch mold dimensions were found. Finally, a finite element model of the new clinch mold was developed and a real clinch mold was made. The comparison between simulated and real clinch joints confirmed the accuracy of the clinching process finite element model.

並列關鍵字

Clinch ； Digital image correlation ； Finite element analysis ； Hyper elastic

參考文獻

[2] J. P. Varis, “ The suitability of clinching as a joining method forhigh-strength structural steel [J] ＂ , Journal of Materials ProcessingTechnology, 32, 2003.

[4] A.A. de Paula , M.T.P. Aguilar , A.E.M. Pertence , P.R. Cetlin ,, “Finite element simulations of the clinch joining of metallic sheets＂, Journal of Materials Processing Technology 182 (2007) 352–357

[5] M. Oudjene , L. Ben-Ayed,, “On the parametrical study of clinch joining of metallic sheets using the Taguchi method＂, Engineering Structures 30 (2008) 1782–1788

[6] C. J. Lee, J. Y. Kim, S. K. Lee, D. C. Ko, B. M. Kim, “Design ofmechanical clinching tools for joining of aluminum alloy sheets＂, Materialsand Design, 31, 2010.

[8] Z. L. Kahn-Jetter, T. C. Chu, Three-dimensional displacement measurements using digital image correlation and photogrammic analysis, Exp. Mech. 30 (1990), p.p. 10-16.