以有限元素法與反應曲面法分析增量式板金成形

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鄭漢威(Han-Wei Cheng) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

以有限元素法與反應曲面法分析增量式板金成形無

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摘要(中)

本文透過有限元素軟體Deform-3D進行方杯增量式板金成形模擬分析，探討沖頭及承板幾何參數對成品最薄厚度、厚度均勻性及最大成形力之影響，並找出最適合之加工條件，達到提升最薄厚度、厚度均勻性及降低成形力的目的。本文設計之增量式板金成形之沖頭及乘板幾何參數包括沖頭邊長、沖頭角隅圓角、沖頭圓角及承板圓角。實驗設計法採用適合建構二階反應曲面之Box-Behnken四因子三水準設計，共計25組模擬實驗點，利用統計軟體Minitab依Deform-3D有限元素軟體分析之結果進行迴歸分析，以建立成品最薄厚度、厚度均勻性及最大成形力之預測模型，進而探討各因子對品質特性之影響，並找出最佳化條件。以有限元素模擬結果對本文所建溝之預測模型進行檢驗，其結果顯示預測模型具有一定準確度。

摘要(英)

An FEM model of incremental sheet metal formed square-cup is developed under the DEFORM-3D software. To observe the influence of punch and back plate geometric parameters to the thinnest thickness, thickness uniformity and maximum forming force of the finished. Also, intend to find the incremental forming condition for optimum design.
　　The factors in the design include the punch geometric parameters, such as side length L, punch corner radius R_cp, punch radius R_p, and the factors of back plate geometric parameters include back plate corner R_b. The experiment adopts 25 groups of analogs with the Box-Behnken design. Using the Minitab software to do the regression analysis and develop the prediction equations. By doing so, it’s excepted using the FEM model and surface response methodology to find the optimum design of the thinnest thickness, thickness uniformity, and maximum forming force. Through the results of FEM simulations to verify the prediction equations with considerable accuracy.

關鍵字(中)

★ 增量式板金成形
★ 有限元素分析

關鍵字(英)

★ Box-Behnken

論文目次

摘要 v
Abstract vi
致謝 vii
圖目錄 xi
表目錄 xiv
符號說明 xvi
第一章導論 1
1-1前言 1
1-2文獻回顧 2
1-2-1板金成形 2
1-2-2增量成形 3
1-3研究動機與目的 8
第二章基本理論 10
2-1 單點增量成形之成品厚度 10
2-2單點增量成形應力理論 11
2-2-1圓周方向應力 13
2-2-2厚度方向應力 13
2-2-3經緯方向應力 13
2-3 Deform-3D破壞問題處理 16
2-4延性破壞準則 18
第三章有限元素法與實驗設計法 21
3-1有限元素法 21
3-1-1有限元素法基本介紹 21
3-1-2 Deform-3D使用流程 22
3-2有限元素模擬設定 24
3-2-1引伸成形模擬驗證 24
3-2-2增量成形之模具建立及加工參數 26
3-2-3材料及臨界破壞值設定 30
3-2-4板材最薄厚度量測及厚度均勻性評估 31
3-2-5增量成形有限元素網格收斂性分析 33
3-3反應曲面法 (Response Surface Methodology，RSM) 37
3-3-1迴歸分析基本理論 37
3-3-3模擬實驗因子與水準 40
3-3-4中心點實驗 40
3-3-5中心點路徑改善 42
3-3-6 Box-Behnken實驗設計法 43
第四章結果與討論 45
4-1模擬結果 45
4-1-1方杯增量成形分析結果例 45
4-1-2中心點實驗結果 50
4-1-3中心點路徑改善結果 55
4-1-4第二次中心點實驗結果 61
4-1-5 Box-Behnken實驗設計點結果 66
4-2迴歸模型建構 68
4-2-1最薄厚度之迴歸分析 68
4-2-2厚度均勻性之迴歸分析 71
4-2-3最大成形力之迴歸分析 74
4-2-4殘差分析 77
4-3 迴歸模型檢驗 81
4-3-1模型檢驗點&單因子檢驗點建立 81
4-3-2檢驗點迴歸模型建立 85
4-4增量成形最佳化分析 97
4-4-1最薄厚度最佳化 97
4-4-2厚度均勻性最佳化 99
4-4-3最佳化分析 102
4-5增量成形加工分析 104
4-5-1增量成形&引伸成形比較 104
4-5-2深度進給量探討 107
4-5-3成形極限深度 109
第五章結論與建議 110
5-1結論 110
5-2建議 111
參考文獻 112

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指導教授

葉維磬(Wei-Ching Yeh)

審核日期

2019-7-29

推文