本研究之目的為探討不同加工因子對管材成形性之影響。在無軸向推力、自由鼓脹的條件下，影響管材鼓脹壓力與成形性之加工因子有入模半徑、管材厚度、鼓脹長度及管材直徑等。為了進行管材液壓鼓脹成形之各項實驗，本論文首先設計並製作出一管材液壓鼓脹成形系統，包括管材液壓鼓脹機台、油壓供應裝置、1比4增壓器及1/2ton小型吊車等。然後在實驗方面，以410℃退火處理過之AA6063-T4鋁合金管為實驗管材，執行不同管材厚度、不同鼓脹長度及不同入模半徑等相關之實驗工作。另外，亦使用有限元素套裝軟體進行上述之加工條件對鼓脹高度、成形壓力及管厚度分佈等之影響。由實驗與解析結果之比較，探討管材於鼓脹成形過程中之變形機制。

The objective of this study is to explore the effects of various process parameters upon the tube formability. In the condition of no axial loads and free bulging, the process parameters that affect tube bulge pressure and formability are die corner radius, tube thickness, bulge length and tube diameter. To proceed the experiments of tube hydro forming, this paper has designed and constructed an experimental system of tube hydroforming comprised of a hard tooling set, hydraulic pressurization circuit, an intensifier and a half ton hoisting device, firstly. In experiments, annealed aluminum alloy tubes are used to carry out the experiments with different tube thickness, bulge length and die corner radius. Furthermore, FEM packages are applied to proceed the analyses of bulge height, forming pressure and tube thickness distribution with forming parameters above. Finally, the comparisons between the analytical and experimental results are discussed to explore the deform action mechanism of tube hydro-forming.

目 錄

論文摘要 Ⅰ
目錄 Ⅲ
圖表索引 Ⅴ
第一章 緒論 1
1-1 前言 1
1-2 THF製程簡介 3
1-3 管材液壓鼓脹成形之文獻回顧 5
1-5 本研究之目的 7
1-6 本論文之架構 7
第二章 管材液壓鼓脹成形之實驗結果 10
2-1 實驗簡介 10
2-2 實驗週邊設備及量測儀器 10
2-2-1管材液壓鼓脹試驗機台 10
2-2-2高壓液體供應設備 14
2-2-3增壓器 14
2-2-4 1/2ton小型吊車 14
2-2-5量測儀器 14
2-3 壓力媒介 15
2-4系統液壓迴路 16
2-5實驗管材之準備 16
2-5-1退火之目的 17
2-5-2退火溫度-時間之設定 17
2-6實驗步驟 17
2-7實驗結果與討論 18
2-7-1實驗參數定義 18
2-7-2實驗結果圖表說明 18
2-7-3實驗規劃 19
2-7-4再現性探討 19
2-7-5管材退火前後之實驗結果 19
2-7-6 不同鼓脹長度及初始厚度之實驗結果 19
2-7-7 不同入模半徑之實驗結果 20
2-7-8 不同壓力下管材鼓脹輪廓之實驗結果 21
2-7-9 不同壓力下管材厚度之實驗結果 21
2-7-10 管材之異方性實驗 21
2-7-11 管材之材料特性實驗 22
2-7-12 實驗結果總結 22
第三章 管材液壓鼓脹成形之有限元素模擬 45
3-1 DEFORM之簡介 45
3-2 DEFORM 2D之分析模式 46
3-3模擬結果與實驗結果之比較 47
3-3-1 不同實驗成形壓力-鼓脹高度圖之比較 47
3-3-2 不同成形壓力下管材鼓脹輪廓及厚度之比較 48
3-3-3 誤差產生原因之探討 48
3-4各項加工因子對成形壓力影響之模擬結果 49
第四章 結論 62
4-1 研究成果之概要 62
4-2 今後研究之課題 63
參考文獻 65
附錄A 螺栓之設計 67

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