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，以其獲得下模穴填充率及軸向成形力峰值為最佳之參數條件。本文之設計參數包含對稱圓錐形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、胚料兩端面的直徑D_1以及胚料中間的直徑D_2；旋轉鍛造加工製程參數包含下模每轉進給率S、上下模具間距c、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，以建立旋轉鍛造成形力及下模穴填充率的預測模型(即反應曲面)，進而探討各因子對旋轉鍛造成形力及下模穴填充率的影響以及最佳設計參數之水準。本文所建立的旋轉鍛成形力及填充率預測方程式與有限元素模擬的結果進行驗證，其結果證明預測模型具有相當的準確度。;In this study, an ideal FE model of cold rotary forging of a spur bevel gear is developed under the Deform-3D software. By this model, the main propose of this paper which is getting the optimum peak force value and filling rate could be found. To achieve the purpose above mentioned, the surface response methodology based on the Box-Behnken design of experiments with six factors will be employed to plan all simulation. There are six factors in the design, including the work-piece geometry with piece volume V, up and down diameter D_(1 ), and center diameter D_2 and the process parameter with feed amount of per revolution S, the distance of the upper and lower die c ,and inclination angle of the upper die γ. 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 peak force value and filling rate.
