超塑成形製程設計及模擬以製作機翼零件

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姓名

藍先進(Hsien-Chin Lan) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

超塑成形製程設計及模擬以製作機翼零件
(Conceiving and Numerically Simulating Various Superplastic Forming Processes for Making an Airplane Strakelet)

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摘要(中)

常見的超塑成形製程多以平板直接吹氣成形，且成形形狀都呈簡易對稱之形狀，少有曲面複雜且幾何外型不對稱之實際工件製作。本論文主要以飛機製造業使用之鋁合金蒙皮零件“機翼前緣整流罩”為超塑成形之研究，所使用之材料為超塑性鋁合金5083，並將材料預折彎加工成V形板後再執行超塑成形。而材料在高溫環境中與模具壁的摩擦效應，將直接影響材料的變形趨勢，為此本論文利用長方形開口盒分析平板工件的成形趨勢，以套用至折彎預成形板材之變形趨勢。除折彎預成形製程外，並以預成形材折彎後之引伸製程、反吹製程、縮小版製程試製，在超塑成形過程中，應用計算壓力-時間成形曲線以控制吹氣壓力。
本論文亦使用有限元素套裝軟體ANSYS/LS-DYNA結合實驗，分析5083鋁合金鈑材之超塑成形製程，並探討機翼前緣整流罩最終厚度分布之影響，以驗證數值模擬分析之可行性與可靠度。ANSYS/LS-DYNA有限元素軟體能提供模具設計人員，在開發階段以數值模擬分析方法瞭解模具之幾何外形，並據以修改模具之外形輪廓，俾利減少測試次數及縮短產品開發時程以便降低成本。本論文以複雜曲面工件為例，所做之數值分析與吹氣超塑成形實驗比對，結果顯示兩者最終厚度分布趨於吻合，可有效預測吹氣超塑成形實驗，具相輔相成的效果。

摘要(英)

Superplastic forming processes usually uses flat sheet to produce simple and symmetrical shapes, however, complicated and non-symmetrical shapes are rarely produced by using superplastic forming. This thesis focuses on using superplastic forming to manufacture the aluminum ” Airplane Fairing Cover” used on an actual commercial airliner. Using the superplastic aluminum alloy 5083, the material was processed into a V-shaped sheet. The Friction effect of between material and die wall in the high-temperature environment will influence the deformation trend of the material. So, this thesis utilizes the forming trend of the rectangle opening box, and then applies to deformation trend of bending preformed sheet. Also try the V-shaped sheet drawing forming process and reverse forming process. The pressure-time curves were calculated for commencing superplastic forming process.
This thesis also uses finite element software suite ANSYS/LS-DYNA to combine the experiment to analyze the superplastic forming process of 5083 aluminum alloy, and discuss the influence of the final thickness distributed of airplane fairing cover in order to verify the numerical simulation analyzed of feasibility and reliability. The ANSYS/LS-DYNA provides a useful tool for designer to understand the geometry appearance of the die in the design level, and reduces the trial tests and shortens the product development process in order to keep costs down. In this thesis, there are compare of numerical analysis and superplastic forming experiments. The results show both the final thickness distribution tends to be consistent. Therefore, the ANSYS/LS-DYNA is capable of predicting the superplastic forming experiment with complementary effects.

關鍵字(中)

★ V形板
★ 複雜曲面
★ 超塑成形
★ 壓力-時間曲線
★ 有限元素分析

關鍵字(英)

★ V-Shape Sheet
★ Irregular Contour Surface
★ Superplastic Forming
★ Pressure-Time Curve
★ Finite Element Analysis

論文目次

摘要 i
Abstract ii
誌謝 iii
目錄 iv
圖目錄 vii
表目錄 xvi
符號說明 xvii
第一章: 緒論 1
1-1 前言 1
1-2 超塑成形概論 2
1-3 超塑成形製程回顧 4
1-4 研究動機 8
1-5 研究方法及步驟 10
第二章: 基本原理及實驗模擬設備 17
2-1 成型理論 17
2-1-1 超塑成形組成方程式 17
2-1-2 長形方盒壓力-時間計算理論 18
2-1-3 圓錐形體壓力-時間計算理論 20
2-2 空孔形成機制 22
2-2-1 空孔成核 22
2-2-2 空孔結合 23
2-3 實驗設備及材料 24
2-4 ANSYS/LS-DYNA有限元素分析軟體 27
第三章: 材料性值測定及長方形開口盒之超塑成形分析 44
3-1 長方形開口盒之成形材料變化趨勢 44
3-2 長方形開口盒之壓力-時間成形曲線計算 46
3-3 LS-DYNA軟體氣吹成形參數設定 48
3-4 成形材料之材料性值測定 53
3-5 長方形開口盒試驗結果與電腦模擬討論 55
第四章: 複雜曲面工件之超塑成形製程分析 69
4-1 複雜曲面工件之成形形狀 69
4-1-1 複雜曲面工件之幾何形狀 69
4-1-2 複雜曲面工件模具配件之位置 70
4-1-3 複雜曲面工件之檢測標準 71
4-2 複雜曲面工件之製程分析 78
4-2-1 折彎預成形之超塑成形方法 78
4-2-2 折彎預成形+引伸沖壓之超塑成形方法 80
4-2-3 折彎預成形+兩階段氣壓超塑成形之方法 83
4-3 複雜曲面工件之壓力-時間成形曲線計算 94
4-3-1 複雜曲面工件之壓力-時間計算推導 94
4-3-2 折彎預成形之超塑成形之壓力-時間成形曲線 102
4-3-3 折彎預成形+引伸製程之超塑成形之壓力-時間成形曲線 103
4-3-4 折彎預成形+兩階段氣壓超塑成形之壓力-時間成形曲線 103
4-4複雜曲面工件試驗結果與電腦模擬討論 109
4-4-1 V型折彎之超塑成形製程試驗結果與電腦模擬討論 109
4-4-2 V型折彎+引伸製程之超塑成形製程試驗與電腦模擬結果討論 112
4-4-3 V型折彎+兩階段氣壓超塑成形製程之試驗結果與電腦模擬討論 118
4-4-4 V型折彎+雙峰等高之超塑成形電腦模擬及分析 122
4-4-5 縮小版雙峰等高之超塑成形製程之試驗結果與電腦模擬討論 124
第五章: 結論 158
參考文獻 162

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指導教授

李雄(Shyong Lee)

審核日期

2013-6-10

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