本文提出了一種新型的散熱片精密鍛造工藝設計，並進行了有限元素分析研究和模擬驗證。這項研究的目的是用金屬板金鍛造（SBMF）代替散熱片的常用鍛造設計，並確定粗鍛在本製程的關鍵。此外，有限元方法（FEM）用於優化散熱片的寬度/可變毛邊可控變形區（W-CDZ / VF-CDZ）的設計，以在0.1(0.1mm/1000mm)的平行度和平面度的關鍵規格範圍內成型散熱片，材料流動，流動速度和應變相關分佈的模擬結果進行模擬分析。實驗和模擬結果顯示，通過適當設計W-CDZ和VF-CDZ，可以通過SBMF成功避免夾料缺陷的發生。在可控和穩定形變區域內，對成型負載，材料流動，流速和應變相關分佈進行了研究。此外，可以充分地改善成型順序和填充率，並且可以實現截面硬度的均勻分佈，從而可以提高使用中的散熱性能。 此外，本研究也將控制變形區的技術應用在複雜曲面醫用刀具，藉由控制局部區域的變形來減少鍛造過程中產生的殘餘應力，取代舊有的製造過程，以解決在後續殘餘應力造成的加工變形且根據體積分配使用廢料率更低的預成型，以達到成本減少與成型性上的改善 ;On this article, a novel precision forging process design for manufacturing radiators is proposed, and numerical research and simulation verification are carried out. The purpose of this study is to replace the commonly used forging design of the heat spreader with sheet bulk metal forming (SBMF) and identify the crucial station of the roughing forging process. In addition, the finite element method (FEM) is used to optimize the design of width/variable flash controllable deformation zone (W-CDZ /VF-CDZ) for the heat spreader to be formed within the critical specifications of parallelism and flatness of 0.1mm. The simulation analysis according to the simulation results of microscopic phenomena forming, material flow, flowing velocity and strain related distribution. The experimental and simulated results indicated that the occurrence of lapping defects can be successfully avoided through SBMF with proper design of W-CDZ and VF-CDZ. The forming load, material flow, flowing velocity and strain related distribution are thoroughly investigated within regions of both controllable and stable deformation zone. Furthermore, the forming sequence and filling ratio can be adequately improved, and a uniformly distributed cross-sectional hardness can be achieved, thereby heat dissipating performance-in-service can be augmented. In addition, this research also applies the technology of controllable deformation zone to medical surgery cutter with complex curve surfaces. By controlling the deformation zone of specific area, the residual stress generated during the forging process is reduced, and also replaced the initial process with improvement process. Meanwhile, the preform with volume distribution theory can strongly reduce the waste, and improve the forming ability.
