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研究生: 朱祐誼
Chu, Yu-Yi
論文名稱: 板材折邊電磁成形之有限元素耦合模擬
Coupled FEM Modeling for Electromagnetic Forming of Sheet Metal Flanging
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: 2007
畢業學年度: 95
語文別: 中文
論文頁數: 58
中文關鍵詞: 耦合有限元素法板材折邊電磁成形
外文關鍵詞: Sheet metal flanging, Electromagnetic forming, Coupling, Finite element method
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  • 近年來,汽車與航空業發展結構輕量化,3C產業亦追求短小輕薄,故鋁合金被應用於板材的需求日益增加,然其在應用上具有可成形性與回彈之問題。高速率成形製程如電磁成形因高應變率與慣性作用,可有效提昇鋁合金之可成形性;同時,由於電磁力近乎於均壓力,故材料幾乎沒有回彈的問題,可用以發展鋁合金板材的各種加工。
    本文應用Ansoft公司之有限元素套裝軟體 Maxwell 3D,利用改變電流值與工件幾何等製程參數來研究電磁成形對於板材折邊模擬之影響,探討成形過程中各種電磁參數的變化,並將所得之電磁參數輸入有限元素套裝軟體LS-DYNA,選擇適用的變形理論與材料參數,模擬板材受電磁力影響之變形,並將兩套軟體耦合模擬工件變形對暫態電磁力的影響。
    由模擬結果可知,成形過程工件的變形會明顯的影響電磁力的大小;同時,無預成形板材角落之成形性受到電磁力不足與餘料太多的影響,成形較其他部位差。本論文得到線圈及胚料的幾何形狀會明顯影響成形效果之結論。

    Recently, the requirement of Aluminum alloy applied to sheet metal is increasing while the automobile and aviation industries develop lightweight structures and the 3C industry produces light and delicate gadgets. However, the current application of aluminum alloy is limited in its material properties, such as formability and springback.
    Electromagnetic forming, a high-energy-rate forming process, can effectively improve the formability of aluminum alloy due to its high strain rate and inertia force. Electromagnetic forming also performs an average pressure distribution of electromagnetic force which allows for forming of aluminum alloy nearly without springback.
    In this research, Ansoft Maxwell 3D and LS-DYNA, softwares of finite element analysis, had been used. The simulation analyzed the effect of electromagnetic forming upon flanging by modulating manufacturing parameters, such as current and geometry of sheet metal. The results from Ansoft were imported into LS-DYNA. Suitable deformation theory and material parameters were chosen to simulate the deformation of sheet metal which was affected by electromagnetic force. The influence of transient electromagnetic force, affected by the deformation of sheet metal, was simulated by coupling two softwares.
    Examining the simulation results, the deformation of sheet metal would affect the magnitude of electromagnetic force, and the corners of sheet metal had worse formability because of the insufficient electromagnetic force and flash. Therefore, it concluded that the geometry of coil and sheet metal had great influence on formability.

    中文摘要............................................I ABSTRACT...........................................II 誌謝...............................................IV 總目錄..............................................V 表目錄............................................VII 圖目錄...........................................VIII 符號說明............................................X 第一章 緒論.......................................1 1-1 前言............................................1 1-2 文獻回顧........................................2 1-3 本文研究目的與範疇..............................6 第二章 電磁成形理論分析...........................8 2-1 金屬成形概論....................................8 2-2 電磁成形技術之介紹..............................8 2-3 電路分析.......................................14 2-4 材料本構方程式.................................15 第三章 電腦數值模擬..............................20 3-1 電磁分析.......................................20 3-1-1 模擬類型及幾何模式...........................21 3-1-2 材料設定.....................................24 3-1-3 邊界設定與驅動源.............................25 3-1-4 參數與解析器設定.............................26 3-2 成形分析.......................................27 3-2-1 幾何建模與配置...............................29 3-2-2 元素選擇.....................................30 3-2-3 材料模式.....................................31 3-2-4 破壞法則.....................................32 3-2-5 邊界條件.....................................33 3-2-6 接觸設定.....................................33 3-2-7 時間步距.....................................34 3-3 收斂性分析.....................................34 3-4 電磁與成形耦合流程.............................36 3-3-1 已變形板材之電磁力計算.......................37 第四章 結果與討論................................38 4-1 電磁模擬結果分析...............................38 4-1-1 磁通密度分布.................................38 4-1-2 電流密度分布.................................39 4-1-3 勞侖茲力分布.................................40 4-2 電磁與成形耦合分析.............................42 4-3 成形模擬結果分析...............................43 4-3-1 具預成形板材於不同能量之成形結果比較.........44 4-3-2 板材形狀對折邊成形之影響.....................46 4-4 勞侖茲力分析...................................47 4-4-1 勞侖茲力之方向...............................47 4-4-2不同能量之勞侖茲力比較........................48 4-4-3不同折邊角度之勞侖茲力比較....................49 第五章 結論與建議................................51 5-1 本文結論.......................................51 5-2 未來建議.......................................52 參考文獻...........................................53

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