加工路徑對傘形齒輪旋轉鍛造製程之有限元素法與反應曲面法分析

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張劭賓(SHAO-PIN CHANG) 查詢紙本館藏

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論文名稱

加工路徑對傘形齒輪旋轉鍛造製程之有限元素法與反應曲面法分析

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摘要(中)

本論文透過有限元素軟體Deform-3D進行旋轉鍛造傘形齒輪模擬分析，研究上模具運動路徑對填充率與應變均勻度的影響。本文之設計參數包含對胚料預成形之參數設計及旋轉鍛造加工製程參數等六個因子。胚料預成形設計參數包含體積V、胚料下端高度h_1、胚料上端直徑d_1以及胚料下端直徑d_2；旋轉鍛造加工製程參數包含下模每轉進給率S以及上模具傾斜角γ。實驗設計採用適合建構二階反應曲面之Box-Behnken 6因子3水準的設計建立共49組模擬，使用統計軟體Minitab依Deform-3D有限元素分析的結果進行回歸分析，以建立旋轉鍛造之填充率及應變均勻度的預測模型，進而探討各因子對填充率及應變均勻度的影響以及最佳設計參數之水準。本文所建立的填充率及應變均勻度預測方程式與有限元素模擬的結果進行驗證，其結果顯示預測模型具有相當的準確度。

關鍵字:旋轉鍛造、有限元素分析、傘形齒輪

摘要(英)

An ideal FE model of cold rotary forging of a spur bevel gear is developed under the Deform-3D software and the upper die motion path on filling rate and equivalent strain uniformity are in this study.
The six factors in the design include the work-piece geometry and the rotary forging process parameters. The work-piece geometry such us piece volume V, Lower height〖 h〗_1, the diameter of the upper and lower diameter〖 d〗_1 〖、d〗_2 and the rotary forging process parameter such us the process parameter with feed amount of per revolution S , and inclination angle of the upper die γ.The experiment adopts 49 groups of analogs with the Box-Behnken design. Use the Minitab software to do the regression analysis and develop the predicted equations. By doing so, it’s excepted using the FEM model and surface response methodology to find the optimum design of the filling rate and equivalent strain uniformity .
In this paper filling rate and strain uniformity prediction equation established with the results of finite element simulations to verify the results show the prediction model with considerable accuracy.

Keywords: cold rotary forging, FEM, spur bevel gear

關鍵字(中)

★ 旋轉鍛造
★ 有限元素分析
★ 傘形齒輪

關鍵字(英)

論文目次

摘要 i
Abstract ii
致謝 iii
目錄 iv
圖目錄 ix
表目錄 xiv
符號說明 xvi
第一章緒論 1
1-1 前言 1
1-2 文獻回顧 3
1-2-1 圓柱及圓環旋轉鍛造鍛粗加工 4
1-2-2 傘形齒輪旋轉鍛造加工 9
1-3 研究動機 14
第二章基本理論 15
2-1旋轉鍛造成型原理 15
2-2 旋轉鍛造運動分析 18
2-3傘形齒輪模具建立 29
第三章有限元素法與實驗設計法 33
3-1有限元素模擬 33
3-1-1有限元素法於塑性加工之應用 34
3-1-2有限元素法之力學模式及數值分析 35
3-2 Deform-3D有限元素軟體[35] 36
3-2-1軟體介紹 36
3-2-2 Deform-3D的使用流程 37
3-3模擬參數設定 38
3-3-1旋轉鍛造加工參數及材料性質 38
3-3-2有限元素網格建構與模擬收斂性探討 40
3-3-3行星路徑軌跡有限元素分析結果例 42
3-3-4螺旋路徑軌跡有限元素分析結果例 46
3-3-5圓形路徑軌跡有限元素分析結果例 49
3-3-6直線路徑軌跡有限元素分析結果例 52
3-4實驗設計法[42] 56
3-4-1反應曲面法(Response Surface Methodology，RSM) 56
3-4-2迴歸分析基本理論 56
3-4-3模擬實驗因子與水準 59
第四章結果與討論 62
4-1模擬驗證 62
4-2旋轉鍛造傘形齒輪結果 67
4-2-1旋轉鍛造傘形齒輪之軸向成形力與行程 67
4-2-2旋轉鍛造傘形齒輪之填充率 70
4-2-3旋轉鍛造傘形齒輪之應變均勻度 73
4-3模型建構 74
4-3-1圓形路徑回歸模型 79
4-3-2直線路徑回歸模型 89
4-3-3模型檢驗 99
4-4旋轉鍛造傘形齒輪之最佳化分析 101
4-4-1圓形路徑之模擬實驗最佳化 101
4-4-2直線路徑之模擬實驗最佳化 104
4-4-2上模具運動路徑對最佳化解的效應 106
4-5品質因子對品質特性之效應 107
4-5-2品質因子對應變均勻度之效應 116
第五章結論與建議 125
5-1結論 125
5-2建議 126
參考文獻 127
附錄A 133
附錄B 136

參考文獻

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指導教授

葉維磬

審核日期

2016-8-16

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