在本碩士論文研究中，製造非標準齒輪的熱間鍛造技術，通過模擬和數值研究進行驗證。研究的目的是為了尋找精密加工鍛造過程中的製程缺陷，並實現多芯電纜剪鉗在閉模熱鍛中形成的非標準齒輪齒，同時取代傳統的熔模鑄造和開模鍛造。此外，為了確定非標準齒輪齒的形成，提出了新型擠出鍛造齒型成型（extrusion-forging teeth forming, EFT）方法，並利用有限元素分析軟體Qform 3D進行模擬研究，並進行實驗研究比較。 特殊非標準齒輪的研究參數對齒型成型進行有條理的分析，並與實驗研究形成鮮明對比。並且提出三種不同的鍛造預製工件進模擬研究分析。基於模擬的結果，已經獲得工件成形，有效應力，有效應變和溫度相關的模擬結果來描述微觀現象。通過與實驗尺寸的比較，驗證了數值模型的準確性。 最後提出了來自鍛造預製工件的所提出的改進幾何形狀以獲得類似的成形情況，同時降低製造費用。對於改進的幾何形狀預成型C，所提出的新型擠出鍛造齒型成型方法的最佳擠出鍛造比(R_x=A_x/A_m ) 和部分面積差比 (r_x=1-A_m/A_x ) 可以分別計算為 R_C = 1.38 和 r_C = 0.28。本研究歷經實際開發鍛造模具與模座已成功鍛製出具精密齒型多芯電纜剪鉗的活動刀跟固定刀。我們希望這一進步可為與任何幾何形狀相關的鍛造非標準齒輪提供有價值且有用的技術參考。 ;In this study, a hot forging process in making non-standard gear will be experimentally as well as numerically researched. The purpose of the research is to look for the crucial station of the finishing forging process and also to realize the particular non-standard gear teeth forming within the closed die hot impression forging associated with multicore cable cutter and replace the traditionally investment casting and open die forging counterparts. Furthermore, in order to make certain realize the non-standard gear teeth forming, the novel extrusion-forging teeth forming (EFT) approach is proposed and simulated from the commercially obtainable finite element software Qform 3D. The processing parameters on the non-standard gear teeth forming are methodically analyzed and also carefully in contrast to experimental research. Three different forged prefabricated workpieces are proposed for simulation analysis. Based on consequences of the simulations, the material distributions associated with forming, stress, strain, and temperature have been obtained to describe the microscopic phenomena. Accuracy from the numerical models have been verified by comparing with experimental dimensions. The proposed modified geometry from the forged preform has been finally proposed to attain a similar forming situation while decreasing manufacturing expenses. The extrusion-forging ratio (R_x=A_x/A_m ) and the fractional reduction in area (r_x=1-A_m/A_x ) of the proposed EFT method can be calculated as R2 = 1.38 and r2 = 0.28 respectively for the modified geometry of preform C. This research has been developed and forged, and the mold and mold base have been successfully integrated and forged to produce a movable blade and fixed blade with precision teethed multicore cable cutters. We expect that this advancement can provide a valuable and useful technical reference for the forging of customized gears associated with any geometry.
