常見的超塑成形製程多以平板直接吹氣成形，且成形形狀都呈簡易對稱之形狀，少有曲面複雜且幾何外型不對稱之實際工件製作。本論文主要以飛機製造業使用之鋁合金蒙皮零件“機翼前緣整流罩”為超塑成形之研究，所使用之材料為超塑性鋁合金5083，並將材料預折彎加工成V形板後再執行超塑成形。而材料在高溫環境中與模具壁的摩擦效應，將直接影響材料的變形趨勢，為此本論文利用長方形開口盒分析平板工件的成形趨勢，以套用至折彎預成形板材之變形趨勢。除折彎預成形製程外，並以預成形材折彎後之引伸製程、反吹製程、縮小版製程試製，在超塑成形過程中，應用計算壓力-時間成形曲線以控制吹氣壓力。 本論文亦使用有限元素套裝軟體ANSYS/LS-DYNA結合實驗，分析5083鋁合金鈑材之超塑成形製程，並探討機翼前緣整流罩最終厚度分布之影響，以驗證數值模擬分析之可行性與可靠度。ANSYS/LS-DYNA有限元素軟體能提供模具設計人員，在開發階段以數值模擬分析方法瞭解模具之幾何外形，並據以修改模具之外形輪廓，俾利減少測試次數及縮短產品開發時程以便降低成本。本論文以複雜曲面工件為例，所做之數值分析與吹氣超塑成形實驗比對，結果顯示兩者最終厚度分布趨於吻合，可有效預測吹氣超塑成形實驗，具相輔相成的效果。 Superplastic forming processes usually uses flat sheet to produce simple and symmetrical shapes, however, complicated and non-symmetrical shapes are rarely produced by using superplastic forming. This thesis focuses on using superplastic forming to manufacture the aluminum ” Airplane Fairing Cover” used on an actual commercial airliner. Using the superplastic aluminum alloy 5083, the material was processed into a V-shaped sheet. The Friction effect of between material and die wall in the high-temperature environment will influence the deformation trend of the material. So, this thesis utilizes the forming trend of the rectangle opening box, and then applies to deformation trend of bending preformed sheet. Also try the V-shaped sheet drawing forming process and reverse forming process. The pressure-time curves were calculated for commencing superplastic forming process. This thesis also uses finite element software suite ANSYS/LS-DYNA to combine the experiment to analyze the superplastic forming process of 5083 aluminum alloy, and discuss the influence of the final thickness distributed of airplane fairing cover in order to verify the numerical simulation analyzed of feasibility and reliability. The ANSYS/LS-DYNA provides a useful tool for designer to understand the geometry appearance of the die in the design level, and reduces the trial tests and shortens the product development process in order to keep costs down. In this thesis, there are compare of numerical analysis and superplastic forming experiments. The results show both the final thickness distribution tends to be consistent. Therefore, the ANSYS/LS-DYNA is capable of predicting the superplastic forming experiment with complementary effects.
