水龍頭之液壓與彎管成形模擬分析與實驗

Simulation and Experiment of Hydroforming and Bending for Making a Faucet

陳庭育(Tingyu Chen)

指導教授 ： 胡惠文

國立屏東科技大學/工學院/車輛工程系所/碩士(2013年)

https://doi.org/10.6346/NPUST.2013.00169

摘要

本論文研究目的為透過液壓與彎管成形的技術來製造一水龍頭。傳統水龍頭多採用鑄造的方式來進行製造，但其製造過程必須在高溫且後處理時有高粉塵汙染。因此在製造水龍頭時採用液壓與彎管成形較傳統鑄造來的乾淨、精準且有效。本論文中所採用成形素材管為SUS304不銹鋼，並透過材料拉伸試驗來獲得其材料機械性質。本研究採用ANSYS/LS-DYNA進行有限元素分析模型建立，模型包含管件(Tube)、模具(Die)、側缸(Punch)等。分析中以多段線性塑性模組將SUS304不銹鋼材料真實應力應變曲線輸入，以模擬出材料於塑性區段的變形行為。成形初始壓力則採用厚壁管理論來進行計算。然而水龍頭的成形參數不只有內壓力，也包含了軸向進給與背桿支撐力。因此透過模擬分析的方式找出最佳的成形負載路徑。彎管成形方面也可透過模擬分析的方式找出內支桿放入管件中最佳的支撐位置。根據分析的負載參數來進行水龍頭試作實驗，透過分析與實驗的厚度分佈與幾何尺寸比對來驗證分析之準確性。

關鍵字

液壓成形 ； 彎管成形 ； 內壓力 ； 軸向缸 ； 多段線性塑性模組 ； 有限元素模型 ； 厚壁管理論 ； 厚度分佈 ； 幾何尺寸

並列摘要

The purpose of this research is to develop the technique of hydroforming and bending for making a faucet. Traditionally, the faucet is made using casting which is a fabrication approach involved high temperature and dusting in post tooling. Hydroforming and bending provide more clean, accurate and efficient approach than casting in fabricating faucet. The tube made from stainless steel SUS 304 is used in this study. Its mechanical properties are obtained using tensile test. Finite element model, including tube, dies and punches, are established using a commercial code ANSYS_LS-DYNA. The true stress-strain curve is then used to enter the commercial code which is used to simulate the plastic deformation of material during the forming process by adopting piecewise linear plasticity model. The initial internal pressure is designed by using the theory of thick-walled cylinder. However, the hydroformibility of faucet depends not only on internal pressure but also on axial punches and counter punch. Simulation is therefore used to find the optimal loading conditions. The simulation of bend forming is also performed to find the optimal position of supported rod which is placed inside the tube.
Experiment is performed to fabricate the prototype of faucets using the simulated loading parameters. The results obtained from simulation and experiment show that good correlations of the distribution of thickness and the profile dimension are obtained.

並列關鍵字

Hydroforming ； Bending ； Internal pressure ； Punch ； Piecewise linear plasticity model ； Finite element model ； Theory of thick-wall cylinder ； Distribution of thickness ； Profile dimension

參考文獻

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