複雜變化曲面之鋁合金自行車車架管件開發

The Development of complex-curved-surface Aluminum Bike Tube

莊志宇(C. Y. Chuang) ； 劉弦錦(C. S. Liu) ； 黃建成(C. C. Huang) ； 邱黃正凱(C. K. Chiuhuang) ； 鄭炳國(P. K. Cheng)

《鍛造》 16卷1期 (2007/06) Pp. 29-35

https://doi.org/10.29791/Forging.200706.0006

摘要

輕量、舒適、美觀是高級自行車訴求之重點，目前全球自行車產業製造技術已趨成熟，由於受到傳統管件加工技術之限制，雖然外觀精美之自行車管件可用沖壓模具配合心軸實作出來，但無法直接作出曲面大變化、造形美觀複雜之自行車管件，需再輔以兩片以上板材沖壓後銲接組裝易使曲面尺寸發生變異之製程，後續騎乘時有可能會因過多銲接而易發生裂損，造成危安事故，因此長久以來自行車車架造型及功能性均難以突破，而管件液壓成形技術提供了能夠製造出之獨特造型及輕量化車架的製程優勢，隨著市場需求的增加，自行車產業已積極導入相關應用。
本文介紹截面變化率大於100%之一體型美觀鋁合金自行車管件如何運用管件液壓成形技術來結合預成形管件加工開發，並從液壓成形性分析，製程規劃、模擬驗證及實際試模…等相關流程作討論，以對研究開發大截面變化率之鋁合金自行車管件有更深入了解。

關鍵字

管件液壓成形 ； 自行車 ； 有限元素分析

並列摘要

Lightweight, comfort and beautiful are the main demands of deluxe bike. Currently, the application of the global bike industry manufacturing technique has already tended maturity. Because of the traditional restriction for the tube forming-manufacturing technology, the shape &function of bike tube is hard to be advanced upgraded for long time. Although the elegant bike tube could be formed by pressing tools with mandrel, the beautiful complicated surface of bike tube with large variation-cross section cannot be manufactured directly and need to be made by welding more than two pressing parts for integration. But welding manufacturing process easily make the curved face size occurrence variation, Influencing the follow-up assembly, beauty and usage. When riding a bike being welded too much, the vibrational shock maybe easily cause brittle cracks on the weiding line, even the bike to suffer damage, and that is the reason why bike knight may be hurt. Because the market reveals more and more needs, tube hydroforming could satisfy the requests by having ability of making the special beauty shape of bike tube and the manufacturing process advantage of the reducing in weight.
This text introduces how the integrated-beauty aluminum bike tube with cross-section variety larger than 100% would be developed by tube hydroforming combining with tube preforming. In order to further understand the research and development of aluminum bike tube with large variation-cross section, the content reveals the formability study of THF bike tube, manufacture process design, simulation verification and real tryout, etc.

並列關鍵字

THF ； Bike ； FEM