擠壓絲攻刀具幾何特徵之最佳化分析

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簡威容(Wei-Rong Jian) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

擠壓絲攻刀具幾何特徵之最佳化分析

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至系統瀏覽論文 (2025-7-20以後開放)

摘要(中)

本文透過有限元素軟體Deform-3D進行擠壓絲攻成形模擬分析，探討M1.2螺絲攻應用於鋁合金7075之攻牙品質，其刀具幾何特徵對於內螺紋牙型填充率及最大扭矩的影響。因此，本文設計之刀具幾何參數包含四面寬、根徑、前端外徑及牙山角度，並利用實驗之內螺紋輪廓與牙型填充率進行模型驗證，確認有限元素分析模型之妥適性。為了分析多因子的品質問題，實驗設計採用適合建構二階反應曲面之Box-Behnken四因子三水準設計，總計25組模擬實驗。經由統計軟體Minitab針對模擬結果進行變異數分析，以建立牙型填充率及最大扭矩之迴歸預測模型，進而探討各因子對品質特性之影響，並找出最佳之刀具設計，達到提升填充率與降低最大扭矩之目的。另外，以有限元素模擬結果對本文所建構之預測模型進行檢驗，其結果顯示預測模型具有足夠的準確度，期望可協助業界於刀具研發之設計改善。

摘要(英)

This study presents a finite element model of forming tap based on the Deform-3D software. Investigating the thread quality of M1.2 tap on 7075 aluminum alloy, and the influence of tool geometric parameters on the thread fill rate and maximum torque. Therefore, the factors of tool geometry, including tool width, root diameter, front-end diameter, and tooth angle. The result of experiments of internal thread profile and thread fill rate as validation of simulations. Its show that finite element model can deal with internal thread problem. 25 sets of simulation experiments are designed to three levels of each factor according to Box-Behnken design, a type of second-order response surface methodology. Analysis of variance(ANOVA) based on the simulation results established the regression equation of thread fill rate and maximum torque by using Minitab software. Depend on the effect of factors with tool geometry, find out the optimal design to increase thread fill rate, and reduce maximum torque in the thread process. Furthermore, the FEM simulation result has been validated by the regression equation, and establish the analysis model has certain accuracy on the internal thread process. This analysis model is expected to support an optimal tool design for the industry.

關鍵字(中)

★ 擠壓絲攻
★ 有限元素分析

關鍵字(英)

★ Forming tap
★ Box-Behnken

論文目次

摘要　i
Abstract　ii
誌謝　iii
圖目錄　viii
表目錄　xii
符號說明　xv
第一章緒論　1
1-1前言　1
1-2文獻回顧　2
1-3研究動機與目的　7
第二章基本理論　8
2-1擠壓絲攻成形原理　8
2-2擠壓絲攻刀具設計　10
2-2-1擠壓絲攻刀具幾何外型　11
2-2-2刀具製程介紹　15
2-3擠壓絲攻實驗流程　15
2-4圖像二值化分析原理　19
第三章有限元素法與實驗設計法　22
3-1有限元素法介紹　22
3-2 Deform-3D有限元素軟體　23
3-3模擬參數設定　25
3-3-1擠壓絲攻分析模型與加工參數的設定　25
3-3-2擠壓絲攻牙型填充率　28
3-3-3有限元素網格收斂性分析　32
3-3-4擠壓絲攻模擬驗證　36
3-4實驗設計法　40
3-4-1反應曲面法　40
3-4-2迴歸分析基本理論　40
3-4-3模擬實驗因子與水準　43
3-4-4中心點實驗　44
3-4-5中心點參數優化　45
3-4-6 Box-Behnken實驗設計法　46
第四章結果與討論　48
4-1模擬結果　48
4-1-1擠壓絲攻成形分析結果例　48
4-1-2中心點實驗結果　61
4-1-3中心點參數優化結果　65
4-1-4 Box-Behnken實驗設計點結果　68
4-2迴歸模型建構　70
4-2-1牙型填充率之迴歸分析　70
4-2-2最大扭矩之迴歸分析　72
4-2-3迴歸模型殘差分析　76
4-3迴歸模型檢驗　79
4-4擠壓絲攻最佳化分析　84
4-4-1牙型填充率最佳化　84
4-4-2最大扭矩最佳化　86
4-4-3 Box-Behnken設計最佳化分析　88
4-5中央合成實驗設計　91
4-5-1牙型填充率之迴歸分析　93
4-5-2最大扭矩之迴歸分析　95
4-5-3迴歸模型殘差分析　98
4-5-4中央合成設計最佳化分析　101
4-5-5中央合成設計與Box-Behnken最佳化結果比較　104
第五章結論與建議　106
5-1結論　106
5-2建議　107
參考文獻　108
附錄A　ImageJ軟體操作流程　111

參考文獻

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[2] Chowdhary, S., Ozdoganlar, O. B., Kapoor, S., DeVor, R., “Modeling and Analysis of Internal Thread Forming”, Trans. NAMRC/SME, Vol.30, pp. 329-336, 2002.

[3] Chowdhary, S., DeVor, R.E., Kapoor, S.G., “Modeling Forces Including Elastic Recovery for Internal Thread Forming”, Journal of Manufacturing Science and Engineering, Vol.125, pp. 681-688, 2003.

[4] Warrington, C., Kapoor, S.G., DeVor, R.E., “Experimental Investigation of Thread Formation in Form Tapping”, Journal of Manufacturing Science and Engineering, Vol.127, pp. 829-836, 2005.

[5] Warrington, C., Kapoor, S.G., DeVor, R.E., “Finite Element Modeling for Tap Design Improvement in Form Tapping”, Journal of Manufacturing Science and Engineering, Vol.128, pp. 65-73, 2006.

[6] Gardner, J.D., Dornfeld, D., “Finite Element Modeling of Drilling Using DEFORM”, Consortium on Deburring and Edge Finishing, Laboratory for Manufacturing and Sustainability, UC Berkeley, 2006

[7] Fromentin, G., Poulachon, G., Moisan, A., Julien, B., Giessler, J., “Precision and Surface Integrity of Threads Obtained by Form Tapping”, Manufacturing Technology, CIRP Annals, Vol.54, pp. 519-522, 2005.

[8] Fromentin, G., Poulachon, G., Moisan, A., “An Experimental and Analytical Method for Investigating Plastic Flow in Form Tapping”, International Journal of Forming Processes, Vol.9, pp. 457-472, 2006

[9] Mathurin, F., Guillot, J., Stéphan, P., Daidié, A., “3D Finite Element Modeling of an Assembly Process with Thread Forming Screw”, Journal of Manufacturing Science and Engineering, Vol.131, pp. 151-158, 2009.

[10] Stéphan, P., Mathurin, F., Guillot, J., “Analytical study of Maximal Tapping Torque during Forming Screw Process”, Journal Materials Processing Technology, Vol.211, pp. 212-221, 2011

[11] Carvalho, A.O., Brandão, L.C., Panzera, T.H., Lauro, C.H., “Analysis of Form Threads Using Fluteless Taps in Cast Magnesium Alloy (AM60)”, Journal of Materials Processing Technology, Vol.212, pp. 1753-1760, 2012.

[12] Huang, X.L., Li, X.F., Zuo, D.W, Miu, H., Shi, D.B., “Effect of Structural Parameters of Extrusion Tap on Torque during Forming Process of Internal Thread by Cold Extrusion”, Tool Engineering, Vol.10, pp.18-22, 2012

[13] Pereira, I.C., Faria, A.E., Da Silva, M.B., “Influence of Feed Rate and Threaded Length in Thread Forming and Tapping Operations”, Lecture Notes in Engineering and Computer Science, Vol.3, pp.1781-1784, 2013.

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[15] Filho, S., Oliveira, J., Arruda, E., Brandão, L., “Analysis of Burr Formation in Form Tapping in 7075 Aluminum Alloy”, The International Journal of Advanced Manufacturing Technology, Vol.84, pp. 957-967, 2016

[16] 周中偉，「微型無屑螺絲攻之幾何特徵設計最佳化與刀具壽命研究」，國立台灣科技大學，碩士論文，民國105年。

[17] Oliveira, J., Filho, S., Brandão, L., “Investigation of the Influence of Coating and the Tapered Entry in the Internal Forming Tapping Process”, The International Journal of Advanced Manufacturing Technology, Vol.101, pp. 1051-1063, 2019

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指導教授

葉維磬(Wei-Ching Yeh)

審核日期

2020-7-30

推文