以有限元素法及反應曲面法分析傘型齒輪之旋轉鍛造加工問題

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蘇耿民(Keng-min Su) 查詢紙本館藏

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機械工程學系

論文名稱

以有限元素法及反應曲面法分析傘型齒輪之旋轉鍛造加工問題

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摘要(中)

本論文透過有限元素軟體Deform-3D進行旋轉鍛造傘形齒輪模擬分析，以其獲得下模穴填充率及軸向成形力峰值為最佳之參數條件。本文之設計參數包含對稱圓錐形胚料預成形之參數設計及旋轉鍛造加工製程參數等六個因子。胚料預成形設計參數包含體積V、胚料兩端面的直徑D_1以及胚料中間的直徑D_2；旋轉鍛造加工製程參數包含下模每轉進給率S、上下模具間距c、上模具傾斜角γ。實驗設計採用適合建構二階反應曲面之Box-Behnken 6因子3水準的設計建立共49組模擬，使用統計軟體Minitab依Deform-3D有限元素分析的結果進行回歸分析，以建立旋轉鍛造成形力及下模穴填充率的預測模型(即反應曲面)，進而探討各因子對旋轉鍛造成形力及下模穴填充率的影響以及最佳設計參數之水準。本文所建立的旋轉鍛成形力及填充率預測方程式與有限元素模擬的結果進行驗證，其結果證明預測模型具有相當的準確度。

摘要(英)

In this study, an ideal FE model of cold rotary forging of a spur bevel gear is developed under the Deform-3D software. By this model, the main propose of this paper which is getting the optimum peak force value and filling rate could be found.
To achieve the purpose above mentioned, the surface response methodology based on the Box-Behnken design of experiments with six factors will be employed to plan all simulation. There are six factors in the design, including the work-piece geometry with piece volume V, up and down diameter D_(1 ), and center diameter D_2 and the process parameter with feed amount of per revolution S, the distance of the upper and lower die c ,and inclination angle of the upper die γ. Use the Minitab software to do the regression analysis and develop the predicted equations. By doing so, it’s excepted using the FEM model and surface response methodology to find the optimum design of the peak force value and filling rate.

關鍵字(中)

★ 旋轉鍛造
★ 有限元素法
★ 反應曲面法
★ 傘齒輪

關鍵字(英)

★ cold rotary forging
★ FEM
★ RSM
★ spur bevel gear

論文目次

摘要 i
Absttract ii
致謝 iii
目錄 iv
圖目錄 vii
表目錄 xii
第一章序論 1
1-1前言 1
1-2文獻回顧 3
1-2-1 圓柱及圓環旋轉鍛造鍛粗加工 4
1-2-2 傘形齒輪旋轉鍛造加工 8
1-3研究動機、目的與方法 10
第二章旋轉鍛造分析 13
2-1旋轉鍛造運動分析 13
2-2成型原理 20
2-3傘齒輪模具之建立 22
第三章有限元素分析與實驗設計法 25
3-1有限元素模擬 25
3-1-1有限元素分析基本理論 25
3-1-2有限元素法之力學模式及數值分析 26
3-2 Deform-3D有限元素軟體[35] 27
3-2-1軟體簡介 27
3-3模擬參數設定 31
3-3-1有限元素法之力學模式及數值分析 31
3-3-2材料性質 35
3-3-3旋轉鍛造加工參數 36
3-4實驗設計法 41
3-4-1反應曲面法(Response Surface Methodology，RSM) 41
3-4-2迴歸分析基本理論 43
第四章結果與討論 47
4-1模擬驗證 47
4-2迴歸分析與檢驗 52
4-2-1旋轉鍛造軸向成形力 52
4-2-2模穴填充率 53
4-2-3傘齒輪旋轉鍛造迴歸分析 57
4-3因子交互作用對最大成形力之效應 70
4-3-1 胚料體積(V)與上模具傾斜角(γ)對成形力的效應 71
4-3-2下模具每轉進給率S與上模具傾斜角γ對成形力的效應 72
4-3-3上下模具間距(c)與上模具傾斜角(γ)對成形力的效應 74
4-4因子交互作用對填充率之效應 76
4-4-1胚料體積(V)與胚料上端面直徑(D_1)對填充率之效應 76
4-4-2胚料體積(V)與下模每轉進給率(S)對填充率之效應 78
4-4-3胚料體積(V)與上下模具間距(c)對填充率的效應 80
4-4-4上下模具間距(c)與上模具傾斜角(γ)對填充率的效應 81
4-5對稱圓錐形胚料幾何特徵對模穴填充率之影響 83
4-6 幾何特徵對應變分佈之影響 90
4-7幾何特徵對應力分佈之影響 92
4-8品質特性最佳化 93
第五章結論與建議 95
5-1結論 95
5-2建議 96
參考文獻 97

參考文獻

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指導教授

葉維磬(Wei-ching Yeh)

審核日期

2015-7-30

推文