本論文透過有限元素軟體Deform-3D進行螺旋齒輪旋轉鍛造製程分析，研究各因子間對品質特性之影響。本文之設計因子包含旋轉鍛造之加工因子以及預成形圓台體胚料之幾何參數。旋轉鍛造製程參數包含上模具傾斜角γ、每轉進給率s，胚料之幾何參數包含胚料高度H、胚料下直徑D，探討對製程中成形力峰值以及模穴填充率之影響，並設計亦料槽以達到減少二次加工之目標。實驗設計採用適合建構二階反應曲面之Box-Behnken 4因子3水準的設計建立共26組模擬，使用統計軟體Minitab依Deform-3D有限元素分析的結果進行迴歸分析，以建立成形力及下模穴填充率的預測模型，求得在成形力最小的情形下，下模穴填充率之可以達到一定水平之最佳設計因子。本文所建立的成形力峰值及填充率預測方程式與有限元素模擬的結果進行比對，其結果證明預測模型具有相當的準確度。;In this study of cold rotary forging of helical gear,we use FEM software Deform3D to anylyze the factors which effect the peak force and the filling ratio in the process.There are four factors in this study, including the workpiece geometry parameters and the process parameters.The workpiece geometry includes height H and down diameter D. The process parameter includes inclination angle of the upper and die feed amount of per revolution s. Our goal in this study is optimizing the peak force value and the filling rate could be found.to achieve this goal,we use the surface response methodology based on the Box-Behnken design of experiments to anylyze the results from FEM model.we use the Minitab software to do the regression analysis and develop the predicted equations,after that we can use the equation to get the optimum design of the peak force value and filling rate. In this paper,we are going to use FEM model to check the accuracy of predicted equations. Keywords: cold rotary forging, FEM, RSM, helical gear
