本論文首先探討平板圓孔凸緣之成形性，然後進行平板圓孔凸緣後進行螺帽鑲嵌之可行性評估。使用材料為不鏽鋼板SUS304與鋁合金板6061。以有限分析軟體”DEFORM 3D”進行平板圓孔凸緣成形之模擬，設計三種不同沖頭外形曲線，改變不同下模具孔徑尺寸及下模具孔徑圓角半徑，探討不同沖頭外形曲線、下模具孔徑及下模具孔徑圓角對圓孔凸緣成形之負載、圓孔凸緣後產品各部份尺寸之影響。分析解果顯示，沖頭外形、下模具孔徑、下模具孔徑圓角對於成形之負載、圓孔凸緣之彎曲輪廓、平行邊長度產生影響。另外亦進行平板圓孔凸緣後螺帽鑲嵌之模擬。探討將螺帽鑲嵌於圓孔平板中之負載及鑲嵌製程之可行性。
最後，進行平板圓孔凸緣成形及螺帽鑲嵌之實驗，驗證解析模式之適用性。結果顯示沖頭外形、下模具孔徑、下模孔徑圓角半徑對於圓孔凸緣之影響，在沖頭最大負載上，模擬與實驗誤差皆在7%以下，螺帽鑲嵌於孔凸緣中之實驗顯示，在不鏽鋼材料上，將螺帽鑲嵌於圓孔凸緣中需要13kN，螺帽承受的力量太大產生變形，而在鋁合金A6061-T6板材上，將螺帽鑲嵌於圓孔凸緣中需要約4kN，使用A6061-O材需要3kN，並在螺帽上並無產生變形之情況。

This study is to investigate the formability of round hole flanging on a flat sheet and nut inlaying in the formed product after hole flanging. The materials used are stainless steel SUS304 and aluminum alloy 6061 sheets. The hole flanging simulations are conducted using a finite element analysis software "DEFORM 3D". With three different punch shapes , different bottom die hole diameters and different bottom die corner radius , the punch load and the dimension of flanged products are discussed. The results show that the punch shape, the bottom die hole diameter and bottom die corner radius effect on the forming load, the curved contour of the round hole flange, and the parallel side length. In addition, the simulation of the nut inlaying after the hole flanging simulation result.
Finally, experiments of flat hole flange forming and nut inlaying are carried out to verify the applicability of the simulation model. The results show that the punch shapes, bottom die hole diameter and bottom die corner radius have significant effects on the round hole flange. The different of the maximum load of the punch between simulation and experimental are less than 7%. Experiments of the nut inlaying after the hole flange show that for stainless steel material 304, a load of 13kN is needed to insert the nut into the round hole flange. But the load is large enough to make the nut deform. For aluminum alloy A6061-T6 sheets only 4kN is needed to inlay the nut into the round hole flange. For aluminum alloy A6061-O sheets 3kN is needed to inlay the nut into the hole flange. No plastic deformation occurred on the nut.

目錄
論文審定書 i
謝致 ii
摘要 iii
Abstract iv
目錄 v
圖目錄 viii
表目錄 xiv
符號說明 xv
第一章 緒論 1
1.1 前言 1
1.2 圓孔凸緣技術簡介 2
1.3 文獻回顧 5
1.3.1 圓孔凸緣技術相關之文獻 5
1.3.2 液壓圓孔凸緣技術相關之文獻 11
1.4 研究動機與目的 14
1.5 論文架構與研究流程 15
第二章 圓孔凸緣成形理論 17
2.1 凸緣理論 17
2.2 彈性回復(Spring back) 23
2.3 不鏽鋼之特性 24
第三章 平板圓孔凸緣製程之有限元素分析 26
3.1 DEFORM 3D模擬軟體介紹 26
3.2 有限元素模型之建立與參數設定 27
3.3 圓孔凸緣之模擬解析結果與討論 32
3.3.1 負載曲線解析 32
3.3.2 沖頭外形與負載之關係 35
3.4 沖頭外形與圓孔凸緣長度之關係 53
3.4.1 沖頭與各部尺寸之關係 54
3.5 圓孔凸緣變形機制 68
3.5.1 不銹鋼SUS304 68
3.6 螺帽鑲嵌解析結果與討論 76
3.6.1 螺帽參數設定 76
3.6.2 負載曲線解析 79
3.6.3 螺帽鑲埋變形機制 80
3.7 鋁合金6061之解析與討論 83
3.7.1 鋁合金A6061負載曲線解析 86
3.7.2 沖頭外形與圓孔凸緣長度之關係 89
3.7.3 螺帽鑲嵌於圓孔凸緣解析 91
第四章 圓孔凸緣沖孔實驗 93
4.1 實驗目的 93
4.2 實驗材料與設備介紹與模具配置 93
4.2.1 實驗材料 93
4.2.2 實驗設備介紹 93
4.2.3 實驗模具配置 96
4.2.4 實驗步驟與規劃 97
4.3 實驗結果討論 99
4.3.1 球體沖頭之比較 100
4.3.2 錐形沖頭之比較 102
4.3.3 橢圓球體沖頭之比較 104
4.3.4 螺帽鑲埋實驗 106
4.4 鋁合金A6061鑲嵌實驗結果 107
4.4.1 鋁合金A6061 107
第五章 結論 111
5.1 平板圓孔凸緣與螺帽鑲嵌之模擬 111
5.2 圓孔凸緣成形及螺帽鑲嵌實驗 112
5.3 今後研究之課題 112

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