液壓成型與傳統加工方法相比，由於液壓成型只具有一個剛性模具或衝頭，變更設計時，因不須考慮公差配合而變得相對容易。也因為只有一個剛性模具或衝頭的緣故，而能製造出更高尺寸精度且更高表面品質的板金件，令液壓成型被廣泛應用於製造航空工業所需之零件。本研究針對液壓成型之板金件材料―鋁合金2024 – T351與2024 – O，及三種參與加工的橡膠材料，根據相對應之拉伸實驗規範分別進行實驗，藉此獲取材料之機械性質。並利用有限元素模擬軟體LS-DYNA進行拉伸實驗模擬，將所獲之結果與拉伸實驗相互比對驗證，以建立材料數值模型。接著以有限元素模擬軟體LS-DYNA建立板金件液壓成型之有限元素模型，進行成型過程與回彈之模擬，並與三個實際案例比對驗證。且針對板金件在進行收縮法蘭折彎時起皺之現象，使用田口方法 直交表進行模擬與分析各因子之貢獻率，得出加壓牆和橡膠墊的最佳相關配置，令板金件起皺之狀況獲得改善。

Hydroforming has only one rigid punch/mold so the design can be changed with lower cost comparing to traditional sheet metal forming process. In addition, it is possible to manufacture blanks with higher formability and higher surface quality, making hydroforming method widely used in manufacturing mechanical components. This study measures the mechanical properties of aluminum alloys and rubber materials (used in hydroforming process) by tensile tests; the related numerical parameters are identified and verified through finite element simulation for the tensile test condition. Several sheet hydroforming finite element models are developed using LS-DYNA, and the hydroforming process is performed and compared with the experimental results. Taguchi method is used for the analysis case that the blanks are wrinkled in the shrinkage flange-bending process; the L_18 orthogonal array is used for the simulation, and the contribution of each factor is analyzed. An optimal set of parameters for the hydroforming process is obtained, which can minimize the wrinkle of the blanks.

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