本論文以製造自行車鋁冠鍛件為研究，由於傳統的製程設計容易發生鍛件缺陷之問題，故此研究提出一種具有可控制變形區(CDZ)的模具毛邊設計，並將數值模擬與實驗設計(DOE)結合以利最佳化製程參數，以最大限度地優先保留鍛件的完整性，同時探討模具磨耗。 本文先以田口(Taguchi)方法進行實驗設計，探討三個設計因子:胚料直徑(D)、胚料長度(L)和模具毛邊設計(F)，對訊噪比(SRN)進行最佳化設計，再結合灰色關聯分析(GRA)得出最佳化之參數設計，另外加以探討利用反應曲面法(RSM)的Box-Behnken設計，對於三個目標反應參數:模具平均磨耗深度(S)、成型負荷(T)和鍛造最後成形時模具與工件之間的距離(C)，進一步得到最佳化之製程參數。根據實驗設計分析結果，指出最佳設計因子為:D=40mm、L=205mm和F=CDZ 1。進而將最佳化之設計因子通過FEA，分別探討在微觀鍛流線(Flow line)的分佈與成形負荷、應力、應變和溫度以及模具設計之影響呈現。為了準確地驗證RSM分析的參數，進行了數值分析和實驗驗證之比對，呈現出高度的合理一致性。 ;This dissertation focuses on manufacturing aluminum crown forgings for shock absorber assembly. Due to the traditional process design is prone to forging defects, this research proposes a die flash design with a controllable deformation zone (CDZ), and finite element analysis (FEA) was combined with response surface method (RSM) to optimize the processing parameters with the aim of minimizing the die wear while the integrity of forgings should be prioritized preserved. This article first uses Taguchi method for design of experiments(DOE), discussing three design factors: billet diameter (D), billet length (L) and die flash design (F), use signal-to-noise ratio (SRN) and gray relational analysis (GRA) to get the optimized parameter design, and discuss the Box-Behnken design using the RSM for three target response parameters: the mean die wear depth (S), the forming load (T) and the distance between the die and the workpiece (C) during the final forging forming process further optimize the process parameters. According to the results of the DOE, it is pointed out that the best design factors are: D=40mm, L=205mm and F=CDZ 1. Furthermore, the optimized design factors are analyzed through the results of FEM, and the influences of flow line and forming load, stress, strain and temperature as well as die design are discussed respectively. In order to accurately verify the parameters of the RSM analysis, a comparison between numerical analysis and experimental verification was carried out, showing a high degree of reasonable consistency.
