金屬薄板剪斷成形之最佳化參數研究

A Study of Parameters Optimization for Metal Sheet Blanking Process

阮上維(Shang-Wei Juan)

指導教授 ： 林瑞璋

國立虎尾科技大學/工程學院/機械設計工程研究所/碩士(2013年)

https://doi.org/10.6827/NFU.2013.00042

摘要

在許多金屬切削加工中，剪斷下料加工為效率最快且能夠大量生產的加工方法，在實際加工板件之前在電腦上進行模擬，可避免傳統的人為經驗判斷與試誤法成行而耗費人工及原料增加製造成本。
利用傳統沖床加工時，零件經過切料後，由於尺寸精度及斷面品質較為粗糙，往往還需要一系列後續的修邊加工，且各加工過程中欲維護沖頭、模具的銳利與精度其花費也相當高。沖壓後的不良現象包括斷面粗糙、尺寸精度不佳等現象。
因此本論文欲對一SPCC金屬薄板沖孔加工件之剪斷面的品質進行改善。據現有沖剪加工機的操作參數以有限元素分析軟體ABAQUS模擬沖剪行為並配合田口方法分析，其中考慮刀具角、間隙值、模具圓角、及壓板壓力等參數對剪斷面的影響，並以切斷面的成形情況與特徵斷面的分佈情況與實際產品進行比對，其比對結果的差異量分別為模掍區1.55% 、斷面區1.3%、撕裂區2.94%，驗證結果趨於相近。
而後再運用田口實驗法，依照剪斷行程建立L_9直交表進行最佳化參數的實驗。產品希望在斷面中的平滑區越大越好因此品質特性為望大。探討成型的結果以及斷面特徵進而得到在定義下最佳優化參數。
研究結果顯示，由田口分析可知，刀具角與壓板力兩種參數對斷面品質影響較大；模具圓角影響較小，而模擬優化後的參數成形其斷面平滑區可提升至73.02%的總厚度。從模擬結果得知，壓板荷重的增加對於平滑區的增加是有利的；而角度較大的沖頭反而造成負面的效果。最後再對此優化參數進行預測、確認實驗，以驗證此優化參數對產品斷面品質有得到改善。並預計可達到減少試模次數、人力、原料浪費。

關鍵字

剪斷加工 ； 有限元素法 ； 田口式實驗方法 ； ABAQUS

並列摘要

Blanking process is one of the fastest and effective method for widely used in production of sheet metal parts. However, the blanking parameters has to be through experience and trial and error method to determine the shape , resulting in waste of manpower and raw materials. Using the finite element method to analyze the blanking parameters to avoid these situation.

In the process of blanking, the cut part due to the dimensional accuracy and the quality is rough sections, often requires a series of follow-up trimming procedure. The cost to maintain the processing punch and the accuracy of die will be very high. The defective phenomena including rough shearing surface. and poor accuracy after the blanking process.
Therefore, the main objective of this research is to improve the defects appeared on shearing surface of a SPCC material blanking product with the Taguchi method .
.
According to the operating parameters of a existing punching machine to simulate the cutting behavior by using the CAE software ABAQUS and with the Taguchi method analysis, Taguchi quality design method is used to find the optimal parameters of experimental press used for blanking of circle sheet metal parts. The four control parameters used in this study are punch degree, die clearance, holder pressure, and the radius of die’s edge. And the cut surface of the forming section of the situation and characteristics of the distribution were compared with the actual product, the amount of difference compared to the results were the roll-over section 1.55%, the shear section 1.3%, fracture section 2.94%. This analysis tends to show similar results.
This study is based Taguchi method, in accordance with blanking journey to establish L_9 orthogonal array, then use the CAE software ABAQUS finite element analysis of the blanking behavior, and to explore the quality of shearing surface and forming the case , then get the best travel parameters.
The results show that, by the Taguchi analysis, the punch degree and the Holder press provide a greater impact on the quality of shear section; die corner less affected. Finally, this optimization parameters to predict the confirmation experiment to verify this optimization parameters on product quality has been improved shear section. And is expected to reduce the number of test mode, manpower, raw material waste.

並列關鍵字

Blanking Process ； Finite Element Method ； Taguchi Method ； ABAQUS

參考文獻

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