民航客機機翼前緣整流罩之超塑成形材料研究

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姓名

張暘青(Yang-Ching Chang) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

民航客機機翼前緣整流罩之超塑成形材料研究
(Superplastic Material Research of Commercial Airliner Wing's Leading Edge Fairing Covers)

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摘要(中)

超塑成形技術的發展、主要用於製造外形輪廓複雜的工件。以往文獻主要以小尺寸且對稱幾何形狀進行超塑成形研究，少有大型且外形輪廓近似實際應用之超塑成形工件。本研究主要目的以超塑成形實際製作民航客機用之鋁合金蒙皮零件(機翼前緣”整流罩”)，使用材料為超塑性鋁合金5083。不同於以往平板直接吹製方式，本研究加入折彎預成形之構想再進行超塑成形，實驗首先進行高溫拉伸以證實材料的超塑性；接著再以一般平板直接吹製長方形開口盒，模擬成形後工件之顯微結構與成形趨勢；根據實驗所取得的資料，討論長方形開口盒成形趨勢與加入折彎預成形進行超塑成形之全尺寸工件的相聯性。藉由檢測零件部位之機械性質與材料顯微結構，以證實材料於超塑成形過程的流動趨勢。為了避免高溫超塑成形過程，對材料顯微結構與機械性質造成不良的影響，本研究提出折彎預成形後再室溫引伸以更進一步縮減成形距離與成形時間，此製程以非超塑性AA5182-H34鋁合金試製並進行SP5083室溫引伸可行性評估。

摘要(英)

Superplastic forming (SPF) can be applied to fabricate complex shape components. Earlier researches mainly focused on small scales and symmetric geometries rather than large scales and practical components. The objective of this study is to use SP5083 aluminum alloys to manufacture the “fairing cover” in an actual commercial airliner’s leading edge using SPF techniques. Instead of directly blow form a plate, we incorporated the idea of using a bent pre-form before the superplastic forming process. First, high-temperature tensile tests were carried out to verify the superplasticity of the material. The microstructures and the forming trends were then analyzed by using a small scaled prototype component which was blow formed directly from a plate. Based on the acquired experimental data, the correlation between the prototype and the full scaled component which was blow formed from the bent pre-form was discussed. The material’s flowing tendency during SPF process was verified by examining the components’ mechanical properties and microstructures. To avoid the negative effects on the microstructures and mechanical properties caused by excessive processing time under high temperature, the idea of deep drawing the bent pre-form was proposed, which can further shorten the distance between the forming material and the mold, therefore decreasing the SPF processing time. AA5182-H34 aluminum alloy was used for the drawing trial and the results were evaluated.

關鍵字(中)

★ 超塑成形
★ 整流罩
★ 超塑性鋁合金5083

關鍵字(英)

★ superplastic forming
★ SP5083
★ fairing cover

論文目次

摘要........................................................................................................................I
目錄 .....................................................................................................................IV
圖目錄...............................................................................................................VII
表目錄 ..............................................................................................................XV
符號說明 .........................................................................................................XVI
第一章：緒論........................................................................................................1
1-1前言.........................................................................................................1
1-2 5083鋁合金的特性簡介........................................................................2
1-3超塑成形概論.........................................................................................3
1-4一般超塑成形製程.................................................................................5
1-5全尺寸工件之超塑成形製程.................................................................6
1-6超塑成形的特性.....................................................................................6
1-7超塑性5083材料選用之考量...............................................................7
1-8研究目標.................................................................................................8
第二章：基本原理...............................................................................................11
2-1超塑成形組成方程式...........................................................................11
2-2超塑成形理論.......................................................................................12
2-3空孔形成機制.......................................................................................14
2-3-1空孔生成......................................................................................15
2-3-2空孔成長......................................................................................16
2-4鋁合金材料的命名規範.......................................................................17
第三章：材料與實驗步驟..................................................................................23
3-1實驗材料...............................................................................................23
3-2實驗設備...............................................................................................24
3-3實驗步驟...............................................................................................26
3-3-1實驗流程......................................................................................26
3-3-2腐蝕與金相觀察..........................................................................27
3-3-3機械性質測試..............................................................................28
第四章：結果與討論..........................................................................................40
4-1 SP5083-H18高溫拉伸試驗.................................................................40
4-2長方形開口盒之超塑成形...................................................................41
4-2-1長方形開口盒厚度分佈..............................................................42
4-2-2 OM空孔狀態觀察......................................................................43
4-2-4 OM微結構金相觀察..................................................................44
4-3全尺寸工件之超塑成形.......................................................................46
4-3-1全尺寸工件之幾何形狀..............................................................46
4-3-2全尺寸工件之檢測標準..............................................................47
4-3-3全尺寸工件超塑成形結果..........................................................48
4-3-4全尺寸工件之厚度分佈..............................................................48
4-3-5全尺寸工件機械性質測試..........................................................51
4-3-6 OM空孔狀態觀察......................................................................51
4-3-7 OM微結構金相觀察..................................................................53
第五章：輔助氣吹成形製程構想......................................................................95
5-1 V型折彎預成形室溫引伸構想...........................................................95
5-1-1室溫引伸試作材料AA5182-H34分析......................................96
5-1-2 AA5182-H34室溫引伸試驗結果..............................................98
5-2 SP5083軟化機制(退火熱處理試驗).................................................99
5-2-1常溫拉伸試驗............................................................................100
5-2-2微硬度試驗................................................................................100
5-2-3 OM微結構金相觀察................................................................101
5-2-4 SP5083室溫引伸材料特性之考量..........................................102
5-2-5 SP5083室溫引伸結果..............................................................103
第六章：結論....................................................................................................113
參考文獻 ...........................................................................................................116

參考文獻

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指導教授

李雄(Shyong Lee)

審核日期

2011-7-22

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