本研究為設計管件液壓沖孔之模具及沖頭外形。使用材料為鋼材SPFC590Y以及鋁合金6005，首先進行拉伸試驗取得材料之塑流應力數據。另外亦將原始材料鋁合金6005進行退火，以探討延展性對於液壓沖孔之影響。並藉由有限元素分析軟體”Deform 3D”進行管件液壓沖孔之模擬，其依據破壞準則為Normalized Cockcroft and Latham (NCL)。並利用模擬與拉伸試驗之結果所求得材料之臨界破壞值，探討各項參數對於液壓沖孔之影響以及液壓沖孔之變形機制。
進行液壓沖孔實驗以驗證有限元素模式之適用性。首先進行液壓沖孔之模具設計，並規劃不同參數進行液壓沖孔實驗，以利探討對於剪斷面之影響。結果顯示內壓力、沖頭外形、衝程對於剪斷面之影響，皆與有限元素模擬結果之趨勢相同，在鋼材之剪斷面解析中，誤差皆於10%以內。最後利用迴歸分析之方式，將殘餘厚度與衝程、內壓力以及管厚之模擬結果推導為經驗公式，再將公式代入其參數並與模擬值互相驗證，以驗證其公式之適用性。經驗公式推得對於液壓沖孔製程控制上能有效利用。

This study is focused on the design of the punch shape and die in tube hydro-piercing processes. At first, the material parameters of carbon steel SPFC590Y and aluminum alloy 6005 are obtained using tensile tests. Aluminum alloy 6005 tubes are annealed to investigate the effects of material ductility on hydro-piercing processes. The flow stress curves obtained are used in the finite element simulations of tube hydro-piercing process with software “Deform 3D”. Ductile fracture criterion of Normalized Cockcroft and Latham is used during the simulations. The critical damage values for the criterion are obtained by comparing simulation results and tensile test data. The effects of various parameters such as the stroke, internal pressure, etc. on hydro-piercing processes and deformation mechanism are discussed.
Experiments are conducted to compare with the simulation results to verify the validity of the analytical models. At first, the die design of hydro-piercing processes were conducted, and then the effects of various parameters on shearing surface are discussed by experiments of hydro-piercing. The experimental results show the same trends with simulation results in the effects of internal pressure, punch shape and stroke on shearing surface. Finally formula for the relationship between residual thickness, internal pressure, stroke and tube thickness are developed by regression analysis. Analytical values from the parameters formula are compared with simulation data to verify the validity of the formula. The formula is useful for process control in the hydro-piercing processes.

論文審定書 i
論文公開授權書 ii
謝誌 iii
摘要 iv
Abstract v
目錄 vi
圖目錄 x
表目錄 xviii
符號說明 xx
第一章 緒論 1
1.1 前言 1
1.2 沖孔技術簡介 2
1.2.1 傳統沖孔製程 3
1.2.2 液壓沖孔製程 4
1.3 文獻回顧 6
1.3.1 延性破壞準則相關之文獻 6
1.3.2 沖孔技術相關之文獻 9
1.3.3 精密沖孔以及微小沖孔技術相關之文獻 12
1.3.4 液壓沖孔技術相關之文獻 14
1.4 研究動機與目的 20
1.5 論文架構與研究流程 20
第二章 材料之機械性質 23
2.1 鋼材SPFC590Y塑流應力之求得 23
2.2 鋁合金6005塑流應力之求得 24
2.2.1 鋁合金6005之單軸拉伸試驗 24
2.2.2 塑流應力之計算 26
2.3 破壞值之求得 31
2.3.1 鋼材SPFC590Y 31
2.3.2 鋁合金6005 33
第三章 液壓沖孔製程之有限元素分析 36
3.1 有限元素模型之建立與參數設定 36
3.2 鋼材SPFC590Y之解析結果與討論 40
3.2.1 沖頭外形與剪斷面之關係 40
3.2.2 沖頭模具之應力分析 44
3.2.3 負載曲線之解析 52
3.2.4 剪斷面與內壓力、材料厚度之關係 55
3.2.5 衝程與殘餘厚度之關係 59
3.3 鋁合金6005之解析結果與討論 62
3.3.1 沖頭外形與剪斷面之關係 62
3.3.2 沖頭模具應力之分析 66
3.3.3 負載曲線之解析 68
3.3.4 剪斷面與內壓力、材料厚度之關係 72
3.3.5 衝程與殘餘厚度之關係 76
3.4 液壓沖孔之變形機制 78
3.4.1 鋼材SPFC590Y 78
3.4.2 鋁合金6005 80
3.4.3 矩形管液壓沖孔之變形機制 84
第四章 液壓沖孔實驗 89
4.1 液壓沖孔模具之設計 89
4.1.1 活塞缸負載之計算 89
4.1.2 活塞缸之設計概念 89
4.1.3 沖孔機構設計 90
4.2 實驗設備與實驗規劃 92
4.3 鋼材SPFC590Y之實驗結果與討論 98
4.3.1 不同內壓力下剪斷面分布狀況 98
4.3.2 沖頭外形與剪斷面之關係 103
4.3.3 不同衝程與殘餘厚度之關係 104
4.4 鋁合金6005之實驗結果與討論 107
4.4.1 不同內壓力下剪斷面分布狀況 107
4.4.2 沖頭外形與剪斷面之關係 110
4.4.3 不同衝程與殘餘厚度之關係 112
4.4.4 破壞準則Brozzo對於液壓沖孔模擬之影響 117
4.5 不同材料與剪斷面之關係 120
第五章 殘餘厚度經驗公式之建立 122
5.1 殘餘厚度與加工條件之關係 122
5.1.1 液壓沖孔參數之規劃 122
5.1.2 經驗公式之建立 128
5.2 無因次化經驗公式 129
5.2.1 鋼材SPFC590Y經驗公式之推導 132
5.2.2 鋁合金6005經驗公式之推導 133
5.3 經驗公式之驗證 136
5.3.1 鋼材SPFC590Y之驗證結果 136
5.3.2 鋁合金6005之驗證結果 137
第六章 結論 140
6.1 液壓沖孔製程之模擬 140
6.2 液壓沖孔之實驗 141
6.3 經驗公式之建立 142
6.4 今後研究之課題 142

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