摘要


本文使用三維有限元素模擬軟體DEFORM分析壓延加工時板材於輥隙內之變形過程。研究的對象有T形異形材壓延與H形異形材壓延。分析模式採用剛塑性模式，並假設壓延時輥輪為剛體，且不考慮壓延過程的溫度變化。
在T形異形材壓延方面，分為單道次壓延與雙道次壓延兩部分，並考慮板材之三次元變形，進行一系列的模擬分析，預測壓延過程中板材的填充率、板寬擴張率、壓延負荷和產品曲率等。將預測的解析值與實驗值比較，以驗証DEFORM模擬軟體之適用性。
在H形異形材壓延方面，探討了壓延過程中板材之應力、應變和速度等分佈狀況，並解析在不同壓下率下之H形翼緣(Flange)凹槽的填充情形，這些解析結果可做為設計H型凹槽壓延製程時之參考。

Finite Element Analysis during Shape Rolling Processes

ABSTRACT
This paper used three-dimensional finite element code-deform to analyze the deformation behavior of material at the rolling-gap during shape rolling of T-profiled and H-profiled sheet. The rigid-plastic model was used. The rolls are assumed to be rigid body and the change of temperate during rolling is ignored.
In T-profiled sheet rolling, 1-pass and 2-pass rolling were included. There-dimensional deformation of the sheet was analyzed and the filling ratio at the roll gap, the spread of the sheet, rolling force, the curvature of products were predicted etc. Comparison between analytical and experimental results was made to verify the suitability of the DEFORM software.
In H-profiled sheet rolling , the stress, strain, velocity distribution of material was investigated and the filling ratio was analyzed at the H shape flange during the different reductions. These results can offer knowledge for the design of actual H-profiled sheet rolling.

目錄

摘要 Ⅰ
目錄 Ⅱ
圖表目錄 Ⅵ
符號說明 Ⅹ
第一章 緒論 1
1-1 前言 1
1-2 冷壓延成形 2
1-3 異形材之發展與製造 2
1-4 塑性加工之力學解析法 4
1-4-1 能量法 4
1-4-2 切片法 4
1-4-3 滑移線場法 4
1-4-4 上界限法 5
1-4-5 有限元素法 5
1-5 文獻回顧 5
1-6 本研究之目的 7
1-7 本論文之架構 7
第二章 有限元素法與模擬軟體簡介 9
2-1 前言 9
2-2 有限元素法概論 9
2-2-1 非限性有線元素法 10
2-2-2 剛塑性有限元素法之基礎 11
2-3 DEFORM模擬軟體之簡介 13
2-3-1 前處理模組 14
2-3-2 模擬引擎 18
2-3-3 後處理模組 18
第三章 T形材壓延加工之模擬分析 19
3-1 前言 19
3-2 解析模式的建構 19
3-2-1 解析模式之基本假設 20
3-2-2 有限元素法之分析模式 22
3-3 單道次壓延之解析結果與討論 22
3-3-1 摩擦因子m對成形特性之影響 23
3-3-2 初始板厚hi對成形特性之影響 23
3-3-3 初始板寬Wi對成形特性之影響 24
3-3-4 凹槽寬度Wc對成形特性之影響 24
3-3-5 輥徑比R1/R2對成形特性之影響 24
3-4 雙道次壓延之解析結果與討論 25
第四章 T形異形材之壓延實驗 54
4-1 前言 54
4-2 實驗目的 54
4-3 實驗設備及實驗方法 54
4-4 實驗設備之校驗 55
4-5 單軸拉伸試驗 56
4-5-1 摩擦因子m對成形特性之影響 56
4-5-2 加工硬化指數n值及強度係數K值 56
4-6 實驗步驟 57
4-7 實驗結果與解析結果之比較 58
第五章 H形材壓延加工之模擬分析 80
5-1 前言 80
5-2 解析模式的建構 80
5-2-1 解析模式之基本假設 82
5-2-2 有限元素法之分析模式 82
5-3 解析結果與討論 83
第六章 結論與建議 91
6-1 研究成果之概要 91
6-2 未來研究方向 92
參考文獻 94

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