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研究生： 陳義凱
chen, yi-kai
論文名稱： 無縫管熱擠型製程參數對偏心量效應之研究
Study on Effect of Process Parameters on Eccentricity of Seamless Tube Hot Extrusion
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： 2013
畢業學年度： 101
語文別： 中文
論文頁數： 64
中文關鍵詞： 熱擠製 、無縫管 、沃斯田鐵不銹鋼 、有限元素分析 、偏心量 、製程參數 、田口實驗設計法
外文關鍵詞： hot extrusion, seamless tube, austenitic stainless steel, finite element analysis, eccentricity, process parameters,, Taguchi experimental design method
相關次數： 點閱：112  下載：3 
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    • 本文針對AISI304沃斯田鐵不銹鋼，進行了無縫管熱擠製程的初步設計，並建立管材熱擠製數值模擬模型，利用有限元素軟體DEFORM-3D對沃斯田鐵不銹鋼管材進行數值模擬分析，獲得應變、應力及負荷位移曲線等。製程參數變量為心軸偏置量、胚料初始溫度、摩擦條件、眼模半徑R角。由田口回應分析可反應出各個因子不同水準間之差異，進而得知各個設計因子對於偏心量之影響，文中並獲得一組最佳化設計的組合參數。
    並進一步探討各因子對偏心量之影響，模擬結果顯示摩擦係數越高，造成偏心量也越大。溫度越高偏心量越大，模具半徑R角小偏心量越小。當給定合理範圍內初始心軸偏置量，產品的偏心量不會被放大。

    The preliminary design of hot extrusion process for the typical AISI304 tube were carried out. The numerical simulation model for hot extrusion was established. The hot extrusion process was analyzed by the finite element software DEFORM-3D. Through the simulation, the detailed distribution such as stress field, stain field, as well as the load-stroke curves were obtained. The process parameters including the eccentricity of mandrel、the initial temperature of billet、friction condition and the angle R of extrusion die. After Taguchi’s response analysis, the differences between the levels among parameters were shown. The influence of each factor for the eccentricity was understood, the optimal design parameters were obtained.
    And conclude the effect of parameters on tube eccentrity of stainless steel seamless tube. Simulation results show that higher the coefficient of friction caused by the eccentricity great. higher of temperature the greater the eccentricity, small eccentricity the angle R of extrusion die.When given a reasonable range of the eccentricity of mandrel,the eccentric amount of the product will not be increased.

    中文摘要 Ⅰ 英文摘要................. Ⅱ 誌謝.................... Ⅲ 總目錄...................IV 表目錄.................. Ⅶ 圖目錄...................IX 符號說明................ XI 第一章 前言.........................................1 1-1緒論............................................1 1-2文獻回顧........................................1 1-3 本文研究範疇....................................5 第二章 不銹鋼無縫管擠製製程與偏心現象...................8 2-1 鋼管擠製生產技術.................................8 2-1-1直接擠製......................................12 2-1-2擠製製程中之材料流動方式.........................13 2-2鋼管擠製模具簡介..................................15 2-2-1 擠製模具設備...............................16 2-2-2模具細部功能簡介.............................16 2-3 鋼管擠製產生偏心之原因............................18 2-4 定義無縫管偏心量.................................18 第三章 不銹鋼無縫管擠製之建模與實驗設計..................21 3-1 3D CAD模型之建立................................21 3-2 材料塑流應力取得.................................28 3-3 模擬之假設模式...................................31 3-4 模擬之製程條件規劃................................32 3-5 收斂性分析......................................34 3-6 建模與真實條件比較................................35 3-7 實驗設計法.......................................36 3-7-1信號雜音比之選擇.............................36 3-7-2變異數分析..................................37 3-8製程參數設計之參數規劃..............................39 3-8-1參數設計....................................39 第四章結果與討論......................................42 4-1量測模擬實驗無縫管之偏心量情況.......................42 4-2田口直交表模擬實驗結果分析...........................43 4-3最佳化參數設計.....................................46 4-4 變異數分析.......................................47 4-4-1偏心量之ANOVA分析............................47 4-4-2各別討論因子對偏心量之影響.....................48 第五章 結論與建議.....................................59 5-1 結論............................................59 5-2 建議............................................61 參考文獻............................................62 表目錄 頁 次 表1-1 本文與相關文獻之研究方向比較…................ 4 表3-1 於DEFORM-3D中物件間關係設定…...............25 表3-2 胚料與模具材料及材料模擬之模式............... 33 表3-3 模擬參數規劃表………………………............. 34 表3-4 模擬擠製製程之收斂分析的精度差異表........... 35 表3-5 製程參數對偏心量之影響及其水準配製........... 40 表3-6 L9直交表................................ 41 表4-1 旋轉產品不同角度.......................... 42 表4-2 XZ平面偏心量(扣除初始偏置量)................ 43 表4-3 偏心量參數因子之各組電腦模擬實驗之S/N比...... 44 表4-4 偏心量之參數因子對S/N比的反應表…............ 45 表4-5 實驗組別與最佳化參數設計之偏心量............ 46 表4-6 偏心量之ANOVA分析......................... 47 表4-7 不同摩擦因子下胚料的流速與擠製力............. 49 表4-8 不同模具R角半徑時胚料動流情況............... 52 表4-9 不同擠製速度下產品管表面溫度........... .... 55 表4-10 模具交界處胚料的溫度...................... 57 表4-11 不同管壁厚度的成品管...................... 58 圖目錄 圖1-1 本文研究流程圖….......................... 7 圖2-1 熱擠製法生產不銹鋼管材過程................. 11 圖2-2 直接擠製法..............…………………….... 12 圖2-3 胚料在擠製過程中於擠壓筒內材料流動的情形...... 14 圖2-4 無縫管擠製模具........................... 15 圖2-5 擠壓筒中胚料與心軸相對位置................. 19 圖2-6 無縫管XZ視圖............................. 20 圖3-1 原型胚料之三維幾何模型和網格模型............. 21 圖3-2 心軸之三維幾何模型…....................... 22 圖3-3 擠壓筒之三維幾何模型...................... 23 圖3-4 擠壓桿之三維幾何模型...................... 24 圖3-5 眼模.................................... 25 圖3-6 胚料網格細密化之網格規劃情形............... 26 圖3-7 最大塑性變形區細化之後網格元素之邊長......... 26 圖3-8 擠製成形時模具與胚料之相互位置配置........... 27 圖3-9 Gleeble3500圓柱壓縮試驗.................. 28 圖3-10 溫度1250℃應變率1/S時的壓縮試片............ 28 圖3-11 等應變率條件下所求取出來的平均塑流應力....... 30 圖3-12 塑流應力修正後輸入DEFORM-3D................ 30 圖4-1 偏心量之參數因子對S/N比的反應圖............. 45 圖4-2 不同定剪摩擦係數之偏心量................... 48 圖4-3 不同溫度之偏心量.......................... 50 圖4-4 不同模具R角之偏心量........................ 51 圖4-5 不同心軸偏置量之偏心量......................53 圖4-6 不同擠製速度之偏心量....................... 54 圖4-7 上下模具示意圖............................ 56 圖4-8 摩擦不均之偏心量.......................... 57 圖4-9 不同壁厚之偏心量...........................58

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