有限元素法與反應曲面法對傘形齒輪旋轉鍛造之模具磨耗分析

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黃乙玄(Yi-Xuan Hwang) 查詢紙本館藏

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機械工程學系

論文名稱

有限元素法與反應曲面法對傘形齒輪旋轉鍛造之模具磨耗分析

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摘要(中)

本文利用有限元素軟體Deform-3D進行旋轉鍛造傘形齒輪模擬分析，研究設計參數對下模具的磨耗深度、應變均勻度與最大磨耗位置點的影響，並利用下模具的最大磨耗深度估計模具壽命。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，並使用統計軟體Minitab依Deform-3D有限元素分析的結果進行回歸分析，透過回歸分析建立二階多項式預測模型，求得下模具的磨耗深度在良好的情形下，應變均勻度最小之最佳化解。本文所建立的磨耗深度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精確度。

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 Bottom Die of Life on maximum wear depth 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 Bottom Die maximum wear depth and equivalent strain uniformity .
In this paper Bottom Die maximum wear depth and strain uniformity prediction equation established with the results of finite element simulations to verify the results show the prediction model with considerable accuracy.

關鍵字(中)

★ 旋轉鍛造

關鍵字(英)

★ rotary forging

論文目次

摘要 i
目錄 viiii
圖目錄 v
表目錄 viii
符號說明 xvii
第一章緒論 1
1-1研究背景與動機 1
1-2 金屬加工方法 2
1-3文獻回顧 6
1-3-1 圓柱及圓環旋轉鍛造鍛粗加工 6
1-3-2 傘形齒輪旋轉鍛造加工 11
第二章基本理論 20
2-1旋轉鍛造成型原理 20
2-2 旋轉鍛造運動分析 24
2-3傘形齒輪模具建立 34
2-4磨耗理論 38
第三章有限元素法與實驗設計法 42
3-1有限元素模擬 42
3-1-1有限元素法於塑性加工之應用 43
3-1-2有限元素法之力學模式及數值分析 44
3-2 Deform-3D有限元素軟體[42] 45
3-2-1軟體介紹 45
3-2-2 Deform-3D的使用流程 46
3-3模擬參數設定 47
3-3-1旋轉鍛造加工參數及材料性質 47
3-3-2 Archard磨耗模型參數 50
3-3-3有限元素網格建構與模擬收斂性探討 51
3-3-4最大磨耗深度有限元素分析結果例 56
3-4實驗設計法[41] 59
3-4-1反應曲面法(Response Surface Methodology，RSM) 59
3-4-2迴歸分析基本理論 59
3-4-3模擬實驗因子與水準 62
第四章結果與討論 65
4-1模擬驗證 65
4-2旋轉鍛造傘形齒輪模擬結果 66
4-2-1旋轉鍛造傘形齒輪之軸向成形力 70
4-2-2旋轉鍛造傘形齒輪之應變均勻度 71
4-2-3下模具之磨耗深度及估計壽命 72
4-2-4下模具發生最大磨耗深度之位置 74
4-3模型建構 81
4-3-1應變均勻度之回歸分析 81
4-3-2最大磨耗深度之回歸分析 85
4-3-3模型檢驗 100
4-4旋轉鍛造傘形齒輪之最佳化分析 101
4-4-1模擬實驗最佳化 102
4-5品質因子對品質特性之效應 108
4-5-1品質因子對應變均勻度之效應 108
4-5-2品質因子對下模具磨耗深度之效應 111
第五章結論與建議 114
5-1結論 114
5-2建議 115
參考文獻 116
附錄A 123
附錄B 127
附錄c 129
附錄D 131

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指導教授

葉維磬(Wei-Ching Yeh)

審核日期

2017-8-21

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