近年來，傳統產業的環保議題與高勞力成本逐漸受到重視，其中傳統油淬回火異形線材進行抽線製程前必須先進行球化退火、酸洗、皂化，至少反覆進行三至四次，直到圓形截面的線材被塑性加工成異形截面的線材，因此加工成本高、耗時且會造成環境污染。
軋輥輥路設計是異形材熱軋製程中的核心部份之一，軋輥輥路設計的主要目的是要確保完軋後成品的剖面正確無虞且表面沒有缺陷存在。本文採用二維熱固耦合廣義平面應變有限元素法來解決上述複雜的異形材熱軋輥路設計問題，尤其在進行多道次異形材熱軋模擬時，二維廣義平面應變法可以節省許多電腦計算所需時間與記憶體。
本文研究的目的旨在解決上述異形材加工製程的問題，文中研究如何結合異形材熱軋製程與線上熱處理生產異形線材，熱軋實驗過程以電磁感應加熱設備將圓形合金鋼線加熱至沃斯田鐵溫度，再利用懸臂式軋機以垂直與水平方式進行反覆塑性加工成異形截面，立即進行線上淬火與回火處理，將異形線之組織從波來鐵轉變成回火麻田散鐵，所有熱軋與熱處理製程可以在同一條產線上完成
本文所開發的異形線材熱軋製程相較於傳統的加工製程，具有高效率、低成本與合乎環保等優點，因為製程中完全不需進行球化退火、酸洗與皂化。此外，合金鋼線利用電磁感應加熱方式加熱時間只需幾秒鐘，因此不會造成鋼線表面發生嚴重氧化與脫碳。
最後，本文進行各種機械性能測試、金相實驗與前沃斯田鐵晶粒觀察，並且將異形線材卷繞成螺旋狀之模具彈簧進行耐久壽命測試，測試結果證實本文所開發之異形線材耐久壽命符合需求。

In recent years, environmental issues and high labor costs for traditional industry have been receiving increasing attention. One example is the manufacturing process of conventional oil tempered shaped wire that is high cost, time-consuming and polluting. The process of annealing or spheroidizing needs to be carried out before the shaped wire drawing processes, and acid pickling, phosphate coating, and wire drawing are required three or four times in sequence until the circular section is formed into a trapezoidal section.
The roll pass design is an essential part of the shape rolling process, and the primary goal of the roll pass design is to ensure that the finished products have the correct profile, and are free of surface defects. In this study, we adopted the 2D generalized plane strain finite element method with thermal-mechanical coupling to solve the complicated shape rolling problem, because the 2D generalized plane strain approach saves computing time and computer memory, which is very useful when several subsequent passes are simulated.
The aim of this study is therefore to attempt to solve the problems of producing shaped wire. This study investigates the shape rolling process combined with the in-line induction heat treatment process for tempered shaped wire. The round wire was heated to austenitic temperature using in-line induction heating equipment, and the wire was formed into a trapezoidal shape using a tandem cantilever type rolling mill, then quenched in water and tempered. Hence, the entire sequence was carried out in a single procedure with an automated line。
The advantages of the manufacturing process of this study are highly efficient, low cost, and more environmentally friendly than the conventional process, because there is no need for acid pickling, annealing or spheroidizing and phosphate coating. And the wire is heated to austenitic temperature by induction heating in a few seconds, so the heating process does not cause oxidation or decarburization on the surface of the steel wire.
Finally, it is evidenced that the mechanical properties, microstructure and the fatigue testing results of the shaped wire all satisfied the requirements.

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