本研究提出一摩擦模型，探討純肩部工具與內嵌式工具在摩擦攪拌銲接過程中之熱傳導現象與材料流動行為，在相同的銲接情況下，比較兩者之模擬結果，結果顯示內嵌式工具相較於純肩部工具，介面0溫度較高，材料攪動深度明顯較深，範圍較廣，而達到更優之銲接強度。同時預測工具與試片介面間之滯滑比，配合實驗溫度量測及剖面觀察材料流動結果，以驗證理論模型之正確性。模擬結果顯示在相同工具擠壓力下，轉速越高，接觸面的滯滑比越大；在相同工具轉速下，擠壓力量越大，接觸面的滯滑比越大。同時實驗所觀察之攪拌區深度與範圍，與理論解析之深度與範圍接近，內嵌式工具點銲之材料流動速率與範圍皆遠大於純肩部工具。工具進給速度加快時，試片整體溫度隨之降低，工具前方之溫度低於工具後方之溫度，前進邊之溫度高於後退邊之溫度，而材料流動速率與範圍隨著進給速度的增加而減少，工具後方之材料流動速度遠高於工具前方之材料流動速度。最後將純肩部工具與嵌入式工具在不同擠壓力量、轉速與進給速度下之試片表面最大溫升，以最小平方誤差法，計算出試片表面最大溫升經驗公式，以便參考。

A friction model is proposed to investigate the heat transfer and the material flow during the friction stir welding (FSW) process using a plain tool and an embedded-rod tool. Results show that under identical welding parameters, the embedded-rod tool has higher interface temperature with larger range of material flow than that of plain tool. The stick/slip ratio between the tool and the specimen is predicted. The theoretical model is verified by measuring the histories of the temperature with examining the observations on the cross-section of specimens experimentally. Theoretical results show that the stick/slip ratio increases with increasing rotational speed under a certain of downward force; the stick/slip ratio increases with increasing downward force under a certain of rotational speed. The computational results of the depth and range of stir zone are in very good agreement with the observations from the experiments. The material flow speed for the embedded tool is much larger than that for the plain tool using the spot welding. With increasing weld speed, the weld temperature decreases, and the temperature in front of the tool is lower than that behind the tool. The temperature at the retreating side is slightly higher than that at the advancing side. Material flow speed and range decrease with increasing weld speed and material flow speed in front of the tool is significantly higher than that behind the tool. The empirical equations of maximum interface temperature rises are obtained by analyzing the maximum interface temperature rises under different downward force, rotational speed and weld speed for the plain tool and the embedded-rod tool using the method of least squares.

誌謝 i
摘要 ii
Abstract iii
目錄 iv
圖目錄 vi
表目錄 ix
第一章 緒論 1
1.1 摩擦攪拌銲接概論 1
1.2 文獻回顧 2
1.3 研究目的 5
1.4 論文架構 6
第二章 理論模型 7
2.1 銲接工具種類 7
2.2 三維圓柱座標系 8
2.3 熱傳模型 9
2.4 黏度模型 11
2.5 材料塑性變形產熱 14
2.6 材料塑性流動模型 15
2.7 試片上表面速度與溫度之計算 17
2.8 有限差分法 18
第三章 結果與討論 23
3.1 工具種類對材料溫度與流動速度的影響 24
3.2 驗證點銲穩態試片溫度分布與材料流動範圍之計算結果 28
3.3 工具擠壓力量對材料溫度與流動速度的影響 32
3.4 工具轉速對材料溫度與流動速度的影響 39
3.5 工具進給速度對材料溫度與流動速度的影響 46
3.6 預測試片表面最大溫升量 60
第四章 結論 66
4.1 結論 66
4.2 未來展望 67
參考文獻 68

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