圓柱齒輪感應硬化特徵預測之研究

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姓名

黃子賢(Zhu-Heang Ng) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

圓柱齒輪感應硬化特徵預測之研究
(A Study on Feature Prediction of Cylindrical Gear Induction Hardening)

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至系統瀏覽論文 (2029-1-30以後開放)

摘要(中)

齒輪製造工序一般從鋼胚加工出齒型，接著進行感應硬化熱處理
以提升齒部強度，最終再進行精加工以達到齒輪精準度。為了響應節
能減碳，省略最終進行精加工工序以達到簡化齒輪製造工序之目的，
針對齒輪於感應硬化熱處理後之特徵進行預測成為實現此目的之重
要工具。本研究將提出應用均勻實驗設計法於圓柱齒輪感應淬火實驗
規劃，並透過徑向基函數建立預測模型以預測齒輪於感應硬化熱處理
後之特徵，且推導出各目標預測方程式。此外，本研究利用有限元素
法模擬齒輪感應淬火，提出使用非均勻磁場模型以獲得更準確的結
果。隨後，透過粒子群最佳化方法求解特定齒輪特徵之加熱控制因數
最佳解。最後，應用最佳解於有限元素模擬出非均勻磁場模型之模擬
結果，並與預測模型預測結果進行比較以驗證非均勻磁場模型之正確
性。同時，透過非均勻磁場模型與均勻磁場模型之模擬結果與預測模
型預測結果進行比較，以驗證使用非均勻磁場模型之必要性。總結，
本研究提出預測模型較適用於預測齒輪感應硬化熱處理特徵之工具。

摘要(英)

Gear manufacturing processes typically begin with shaping the teeth from a steel blank, followed by induction hardening to enhance tooth strength. Subsequently, precision machining is performed to achieve gear accuracy. In response to energy conservation and carbon reduction, the final precision machining step is omitted, simplifying the gear
manufacturing process. To achieve this goal, predicting the characteristics of gears after induction hardening becomes a crucial tool. This study proposes the application of uniform experimental design for experimental planning of cylindrical gear induction hardening. A predictive model is established using radial basis functions to anticipate gear characteristics after induction hardening, with the derivation of respective target prediction equations. Additionally, finite element analysis is employed to simulate gear induction hardening, advocating the use of a non-uniform magnetic field model for enhanced accuracy. Subsequently, particle swarm optimization is utilized to determine optimal heating control factors for specific gear features. Finally, applying the optimal solution to finite
element simulation produces results for the non-uniform magnetic field model, validated against predictive model outcomes. A comparison between non-uniform and uniform magnetic field models and predictive model results validates the necessity of employing a non-uniform magnetic field model. In conclusion, this study proposes that the predictive model is more suitable for forecasting characteristics in the induction.

關鍵字(中)

★ 齒輪感應硬化熱處理
★ 齒輪特徵預測
★ 均勻實驗設計法
★ 有限元素法
★ 徑向基函數
★ 粒子群最佳化

關鍵字(英)

★ Gear induction hardening
★ Gear feature prediction
★ Uniform design experiment method
★ Finite element analysis
★ Radial basis functions
★ Particle swarm optimization

論文目次

摘要 i
Abstract ii
謝誌 iii
目錄 iv
圖目錄 vii
表目錄 xi
符號對照表 xiii
第1章緒論 xviii
1-1 研究背景 xviii
1-2 研究動機與目的 xx
1-3 文獻回顧 1
1-4 論文架構 2
第2章齒輪熱處理之基礎理論 4
2-1 齒輪嚙合原理 4
2-2 感應加熱之基本原理 5
2-2-1 電磁感應原理 5
2-2-2 磁滯損失、渦電流損失與集膚效應 8
2-2-3 鄰近效應與邊界效應 12
2-3 淬火 14
2-4 金屬相變化 17
2-4-1 沃斯田鐵 18
2-4-2 肥粒鐵 19
2-4-3 變韌鐵 19
2-4-4 波來鐵 20
2-4-5 麻田散鐵 21
2-5 綜合歸納 22
第3章齒輪熱處理實驗規劃與預測模型建立 23
3-1 均勻實驗設計法 23
3-2 應用均勻設計法於實驗規劃 25
3-3 齒輪與感應線圈之幾何設計 27
3-4 進行實驗與量測 28
3-5 實驗結果與數據 40
3-6 應用ISIGHT建立預測模型 42
3-7 推導各目標預測方程式 48
第4章齒輪於非均勻磁場之感應淬火模擬 53
4-1 COMSOL多物理軟體介紹 53
4-2 感應淬火模擬之概論 55
4-3 非均勻磁場模型之幾何建立 57
4-4 材質之選定 61
4-5 感應加熱模型之建立 65
4-6 淬火模型之建立 74
4-7 非均勻磁場模型之模擬結果 77
第5章熱處理控制因數之最佳解及模型驗證 81
5-1 熱處理控制因數之最佳解 81
5-2 驗證非均勻磁場模型之正確性 83
5-2-1 變形量 84
5-2-2 表面硬度 85
5-2-3 硬化層深度 86
5-2-4 結果比較 87
5-3 非均勻磁場模型與均勻磁場模型之比較 89
5-3-1 變形量 91
5-3-2 表面硬度 92
5-3-3 硬化層深度 93
5-3-4 結果比較 94
5-4 綜合歸納 96
第6章總結與未來展望 97
6-1 總結 97
6-2 未來展望 99
參考文獻 101
附錄Ⅰ 104
作者介紹 112

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指導教授

吳育仁(Yu-Ren Wu)

審核日期

2024-1-29

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