旋轉鍛造螺旋齒輪製程分析

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姓名

劉赫(Ho Liu) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

旋轉鍛造螺旋齒輪製程分析

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摘要(中)

本論文透過有限元素軟體Deform-3D進行螺旋齒輪旋轉鍛造製程分析，研究各因子間對品質特性之影響。本文之設計因子包含旋轉鍛造之加工因子以及預成形圓台體胚料之幾何參數。旋轉鍛造製程參數包含上模具傾斜角γ、每轉進給率s，胚料之幾何參數包含胚料高度H、胚料下直徑D，探討對製程中成形力峰值以及模穴填充率之影響，並設計亦料槽以達到減少二次加工之目標。實驗設計採用適合建構二階反應曲面之Box-Behnken 4因子3水準的設計建立共26組模擬，使用統計軟體Minitab依Deform-3D有限元素分析的結果進行迴歸分析，以建立成形力及下模穴填充率的預測模型，求得在成形力最小的情形下，下模穴填充率之可以達到一定水平之最佳設計因子。本文所建立的成形力峰值及填充率預測方程式與有限元素模擬的結果進行比對，其結果證明預測模型具有相當的準確度。

摘要(英)

In this study of cold rotary forging of helical gear,we use FEM software Deform3D to anylyze the factors which effect the peak force and the filling ratio in the process.There are four factors in this study, including the workpiece geometry parameters and the process parameters.The workpiece geometry includes height H and down diameter D. The process parameter includes inclination angle of the upper and die feed amount of per revolution s.
Our goal in this study is optimizing the peak force value and the filling rate could be found.to achieve this goal,we use the surface response methodology based on the Box-Behnken design of experiments to anylyze the results from FEM model.we use the Minitab software to do the regression analysis and develop the predicted equations,after that we can use the equation to get the optimum design of the peak force value and filling rate. In this paper,we are going to use FEM model to check the accuracy of predicted equations.
Keywords: cold rotary forging, FEM, RSM, helical gear

關鍵字(中)

★ 旋轉鍛造
★ 螺旋齒輪

關鍵字(英)

論文目次

目錄
摘要 i
Abstract ii
致謝 iii
第一章序論 1
1-1前言 1
1-2文獻回顧 4
1-2-1旋轉鍛造鍛粗加工 4
1-2-2 齒輪旋轉鍛造加工 7
1-2-3 螺旋齒輪鍛造加工 10
1-2-4填充率文獻探討 10
1-3研究動機、目的與方法 11
第二章旋轉鍛造運動分析 15
2-1旋轉鍛造運動分析 15
2-2上模接觸分析 23
2-3螺旋齒輪模具之建立 25
第三章有限元素法與實驗設計法 29
3-1有限元素模擬 29
3-1-1有限元素分析基本理論 29
3-1-2有限元素法之力學模式及數值分析 30
3-2 Deform-3D有限元素軟體[40] 31
3-2-1軟體介紹 31
3-2-2 Deform-3D的使用流程 32
3-3模擬參數設定 34
3-3-1有限元素法之力學模式及數值分析 34
3-3-2材料性質 37
3-3-3旋轉鍛造加工參數 38
3-3-4胚料參數 39
3-3-5路徑軌跡有限元素分析 40
3-4實驗設計法 42
3-4-1反應曲面法(Response Surface Methodology，RSM) 42
3-4-2迴歸分析基本理論 46
第四章結果與討論 49
4-1模擬驗證 49
4-2迴歸分析以及品質特性之探討 53
4-2-1旋轉鍛造軸向成形力 53
4-2-2填充率 55
4-3旋轉鍛造迴歸分析 58
4-3-1成形力峰值迴歸分析 59
4-3-2填充率迴歸分析 65
4-4迴規模型檢驗 71
4-5 因子與反應之效應 72
4-5-1 上模傾斜角(γ)以及進給率(s)對成形力峰值之探討 72
4-5-2 上模傾斜角(γ)以及胚料高度(H)對成形力峰值之探討 74
4-5-3胚料高度(H)胚料下直徑(D)對成形力峰值之探討 77
4-5-4上模傾斜角(γ)以及進給率(s)對填充率之探討 78
4-5-5進給率(s)以及胚料高度(H)對填充率之探討 80
4-5-6胚料高度(H)胚料下直徑對填充率之探討 82
4-6品質特性最佳化 84
4-7等效應變及等效應力之探討 86
4-7-1等效應變探討 86
4-7-2 等效應力探討 89
4-8旋轉鍛造傳統鍛造比較 91
4-9填充率探討 91
第五章結論與建議 96
5-1 結論 96
5-2 建議 96
參考文獻 97
附錄 102

參考文獻

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指導教授

葉維磬

審核日期

2018-8-16

推文