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  • 學位論文

6061鋁合金輪圈近淨成形鍛造成形性之分析

Analysis of The Formability in Near-net-shape Forging of 6061 Aluminum Alloy Rim

指導教授 : 林維新
共同指導教授 : 許源泉(Yuan-Chuan Hsu)
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摘要


在全球面臨能源危機與原料價格飆漲的情況下,汽車零組件的輕量化與省料化,進而節省能源為必然之趨勢。鍛造技術的運用不但能符合前述條件,而且其強度、安全性又較其他金屬成形為佳,故將鍛造技術之研發運用在相關零組件上深具發展潛力,由於鍛造輪圈擁有極佳的機械性能,相較於傳統式的鑄造輪圈,更能符合現代汽車消費市場對於安全性能的高度需求以及利用汽車輕量化來節省能源之環保訴求。 鋁及鋁合金具有一系列優良特性,諸如密度小,比強度和比剛性高、抗衝擊性能好、耐腐蝕性好、導熱散熱性好、回收再生性好等,是汽車輕量化的首選材料。 本研究是在模具開發初期運用DEFORM-3D有限元素分析軟體針對6061鋁合金材料,對輪圈近淨成形鍛造進行模擬分析,並預測其鍛造所需壓力,在模擬結果評估最佳化的狀態下進行模具製作,並藉由工法的改變,有效的降低鍛造溫度,經由近淨成形鍛造的流線維持與鍛造溫度降低構成應變強化的效果來達到輪圈強度的提升,並由拉伸試驗確認其機械性質與傳統輪圈鍛造工法之輪圈強度差異。 研究結果發現,藉由輪圈鍛造的工法改良,可有效的提升輪圈鍛造後之降伏強度與抗拉強度,但強度提升的同時會形成部分區域的延伸率下降,故在製程設計時必須做出適當的調配與取捨。

並列摘要


A global energy crisis and soaring raw material prices have prompted energy-saving trends this century, namely producing lightweight auto parts and using less material. The application of the forging technique is in line with the above trends. In addition, forged products are stronger and safer than metals shaped using other methods. Consequently, the application of the forging technique to the manufacture of parts and components is of great potential. Forged wheel rims possess excellent mechanical properties. When compared with traditional cast wheel rims, forged wheel rims are safer and lighter. Faced with growing cost pressure, major car manufacturers have developed strategies to purchase parts and components worldwide. Aluminum alloy possess many excellent characteristics, for instance, the small density, and the advantage on the strength, rigidity, impact function, corrosion, and recycling, etc. therefore the aluminum is the best choice material to use on lightweight automotive. On the primary stage of tooling development, use Deform 3D finite element analysis software to simulate the AL 6061 wheel rims near net shape forging process. The analysis to predict the forging pressure requirement, according to the simulation results to assess the best status of tooling build-up. The strength of forging wheel rims will increase by improve the forging skill, reduce the heating material temperature, and use the near net shape forging to produce the forging flow line with lower forging temperature to cause strain hardening. Then compare the mechanical properties with traditional forging method by tensile test to approve the process. The result shows that the forging wheel rims effectively enhance the yield strength and tensile strength by improve forging process. But the higher mechanical properties can drop the elongation on some parts. In conclusion, it needs to make the appropriate distribution and to have a choice between the mechanical properties and the measure temperature on the process design stage.

參考文獻


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