近年來輕量與高強度管件已被廣泛應用於汽車工業與各種領域，特別是矩形管件。本文以鋁合金AA6061-O管材進行液壓複合成形製程製作矩形斷面管件，而從文獻中得知，以液壓複合成形製程成形矩形管件所需之成形內壓力與閉模力皆低於直接鼓脹成形製程。
本文之實驗機台採用本實驗室自行開發之液壓試驗機，其內壓力可加壓至30MPa，軸向推桿之推力可達40噸。本文將以有限元素套裝軟體DEFORM 2D分析直接鼓脹成形製程與液壓複合成形製程之差異，而複合成形製程又分為無預成形及預成形後壓縮。以有限元素軟體建立模組時須考慮的條件包含材料性質、內壓力、模具進給速度及模具的幾何形狀，並從模擬結果討論成形所需閉模力、成形內壓力及管件之厚度分布。最後，比較實驗結果與模擬結果，驗證有限元素模組之適用性。

Lightweight and high-strength tubes have been widely used in automobile industry and other various fields recently, especially rectangular tubes. Compound processes involved hydroforming and crushing are used in manufacturing a rectangular cross-section tube of aluminum alloys AA6061-O. It is known that the internal pressure and the clamping forces of the die needed in compound process are much less than those in the expansion process.
In this study, a self-designed hydroforming test machine with a 30MPa of internal pressure and a capacity of 40 tons of axial feeding is used. Both of expansion and compound process tests will be conducted. The compound process is divided into directly crushing and crushing after preforming. A finite element simulation software DEFORM 2D is used to establish compound process analytical models with consideration of material setting, internal pressure, moving die feeding rate, and die shape. From the simulation results, thickness distribution, clamping force and forming pressure are discussed. Finally, experimental results will be compared with simulation results to verify the applicability of the finite element models.

論文審定書 i
謝誌 ii
摘要 iii
Abstract iv
目錄 v
圖目錄 viii
表目錄 xii
符號說明 xiii
第一章 緒論 1
1-1 前言 1
1-2 管材液壓成形製程之簡介及應用 3
1-2-1 管材液壓成形之發展近況 3
1-2-2 液壓成形製程之優缺點 4
1-2-3 液壓成形之應用實例 5
1-2-4 液壓成形之影響因素 6
1-3 文獻回顧 9
1-4 研究動機與目的 11
1-5 論文架構與研究流程 11
第二章 矩形管之液壓複合成形模具設計 13
2-1 前言 13
2-2 成形內壓力分析 13
2-3 設計概念與原理 14
2-4 管材成形前後周長計算 17
2-5 鋁合金 AA6061-O之單軸拉伸試驗 19
2-5-1 管材之單軸拉伸速度 19
2-5-2 萬能拉伸試驗機 19
2-5-3 拉伸試片之製作與規格 20
2-5-4 材料塑流應力之求得 21
2-5-5 拉伸試驗結果 22
第三章 矩形管之液壓複合成形有限元素分析 26
3-1 前言 26
3-2 模擬分析之基本假設 26
3-3 直接鼓脹成形 26
3-3-1 幾何模型建立 27
3-3-2 參數設定 27
3-3-3 模擬結果 28
3-4 直接複合成形 30
3-4-1 幾何模型建立 30
3-4-2 參數設定 31
3-4-3 成形負載路徑之探討 32
3-4-4 成形內壓力對後圓角半徑之影響 32
3-4-5 厚度分布 34
3-4-6 成形所需閉模力 35
3-5 管材之預成形 36
3-5-1 尺寸定義 36
3-5-2 預成形至不同寬度之厚度分布 37
3-6 圓角模具液壓複合成形解析 38
3-6-1 幾何模型建立 38
3-6-2 參數設定 39
3-6-3 成形負載路徑之探討 39
3-6-4 厚度分布之探討 45
3-6-5 成形負載之探討 46
3-7 直角模具液壓複合成形解析 47
3-7-1 幾何模型建立 47
3-7-2 參數設定 48
3-7-3 成形後圓角半徑之定義 48
3-7-4 成形負載路徑之探討 49
3-7-5 厚度分布之探討 54
3-7-6 成形負載之探討 58
3-7-7 不同摩擦係數對成形結果之影響 59
3-8 各組矩形管成模具之特性比較 61
第四章 液壓成形實驗 63
4-1 實驗目的 63
4-2 預成形後管材之外型測 63
4-2-1 幾何模型建立與參數設定 63
4-2-2 圓柱輔助成形結果比較 65
4-2-3 管材成形後之高度預測 67
4-3 模具配置與設計 68
4-4 實驗設備 74
4-5 實驗步驟 77
4-6 實驗結果與解析比較 79
4-6-1 管材之預成形 79
4-6-2 直角模具液壓複合成形 82
第五章 結論 90
5-1 矩形管之液壓複合成有限元素分析 90
5-2 管材之預成形實驗 90
5-3 矩形管之液壓複合成實驗 91
5-4 今後研究之課題 91
參考文獻 92

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