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研究生： 毛慶中
Mao, Ching-Chung
論文名稱： 模具表面形貌對精微鍛粗之摩擦效應
Effect of surface topography of die on friction for micro upsetting
指導教授： 李榮顯
Lee, Rong-Shean
學位類別： 碩士
Master
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2005
畢業學年度： 93
語文別： 中文
論文頁數： 76
中文關鍵詞： 精微鍛粗 、表面形貌 、非穩態摩擦
外文關鍵詞： Micro upsetting, Surface topography, Non-steady-state friction
相關次數： 點閱：173  下載：5 
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    • 中文摘要

    精微成形中的尺寸效應不僅只限於材料性質，對於成形試件與模具間的摩擦效應也須詳細評估。目前精微成形中關於摩擦現象，多以封閉、開放潤滑區的分佈進行討論，卻未涉及表面形貌對於摩擦之影響。本文製作出研磨、放電加工與車削之模具表面形貌，搭配精微黃銅試件與潤滑劑進行鍛粗與圓環壓縮實驗，研究模具表面形貌對於精微成形的摩擦影響。透過有限元素法軟體模擬試件端面摩擦情況，將精微鍛粗中因非穩態摩擦所造成的試件端面錯位、挫曲情況以模擬方式重現，並與實驗的臨界偏心距離比較。此外，依據實驗鍛粗試件端面因潤滑失效所造成的內、外分區現象，分區設定摩擦因子以有限元素法模擬成形負荷並與實驗結果進行比較。
    實驗結果顯示表面形貌具方向性特徵的車削模具，對於精微尺度下的摩擦現象有明顯的改善，並減少精微鍛粗中試件發生挫曲的機會。同時，透過設定內、外分區摩擦因子，可將精微鍛粗的成形負荷模擬誤差有效降低。

    BSTRACT
    The size effect for micro forming appears not only on the properties of material, but also on the friction between specimens and dies. Recently, the friction effects for micro forming were studied on the distribution of closed and open lubricant pockets, but not no surface topography. This thesis studies the effect of surface topography of dies on friction for micro forming. Micro brass specimens、lubricant and differential surface topography of dies that fabricated by polishing ,EDM and turning are used in upsetting and ring testes. According to the non-steady-state friction on the end surface of cylinder of the deflection and buckling of cylinder were reproduced by FEM simulation and compared with the critical offset distances measured by the experiment. Furthermore, the values of the friction factors by inner and outer areas on the end surface of cylinder were set in simulation according to the lubricant failure of experimental result of upsetting. The simulated forming load was compared with those by experiment.
    The experimental results indicated that the turning dies with directional texture on surface topography could improve the friction effect in micro scale, and reduced the buckling of cylinder specimens significantly. By setting the inner and outer areas on the cylinder ends with different values of friction factor could also reduce the inaccuracy of load simulation in micro upsetting.

    總目錄 中文摘要…...........................................................Ⅰ 英文摘要.............................................................Ⅱ 誌謝.................................................................Ⅲ 總目錄...............................................................Ⅳ 表目錄...............................................................Ⅶ 圖目錄….............................................................Ⅷ 第一章 緒論.......................................................1 1-1 研究背景......................................................1 1-2 研究動機......................................................5 1-3 文獻回顧......................................................8 1-4 研究範疇與方法................................................14 1-5 本文流程架構..................................................15 第二章 實驗方法...................................................16 2-1 實驗材料......................................................16 2-1-1 七三黃銅成分與顯微組織........................................17 2-1-2 七三黃銅硬度..................................................18 2-2 試件模具製作..................................................21 2-3 試件、模具表面形貌製作........................................23 2-4 表面形貌參數與實驗設備........................................26 第三章 模擬方法...................................................29 3-1 模擬規劃......................................................29 3-1-1 模擬假設模式..................................................29 3-1-2 圓環、鍛粗模擬設定............................................31 3-2 挫曲現象......................................................32 第四章 實驗、模擬結果與討論.......................................37 4-1 實驗結果......................................................37 4-1-1 實驗前、後的模具與試件表面形貌................................37 4-1-2 圓環壓縮實驗結果..............................................46 4-1-3 鍛粗實驗結果..................................................49 4-2 模擬結果......................................................53 4-2-1 收斂性分析....................................................53 4-2-2 臨界挫曲應力..................................................54 4-2-3 挫曲模擬之邊界條件…..........................................55 4-2-4 錯位、挫曲之偏心距離..........................................57 4-2-5 模擬成形負荷與實驗比對........................................62 4-3 討論..........................................................64 4-3-1 表面形貌與摩擦................................................64 4-3-2 試件實驗前-後表面形貌.........................................67 4-3-3 成形負荷之模擬................................................68 第五章 結論與建議.................................................69 5-1 結論..........................................................69 5-2 建議..........................................................71 参考文獻..............................................................73 自述..................................................................76

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