相較於傳統沖壓成形技術，管材液壓成形是一種相當新穎之成形技術，但在製程參數及模具設計等相關資料庫與知識技術上仍相當缺乏。本論文將決定管材之材料性質與成形極限以探討管材之成形性。
本論文首先針對管材無軸向進給之鼓脹成形提出一數學模式以探討在不同加工條件下管材之塑性變形行為。推導數學模式過程中，將假設管材於鼓脹區之外形為橢圓曲面、管材於鼓脹區之厚度為非均一分佈以及管材與模具間之介面為固著模式。在此固著模式中，管材接觸模具後將不移動或滑動。使用此數學模式有系統地探討了入模半徑、鼓脹長度、異向性以及管材初始厚度等不同成形參數對成形壓力之影響。
接著，應用鼓脹試驗數據提出一數學模式以決定管材之塑流應力。實驗方面將針對鋁合金以及不?袗?管材進行鼓脹試驗。鼓脹試驗過程中將量測管材於極點處之厚度與半徑以及成形壓力。為探討異向性，將以拉伸試驗求取異向性r值。由上述之實驗數據，將可以此數學模式推導出管材於雙軸應力態下之塑流應力。將所得之塑流應力代入有限元素軟體進行管材液壓鼓脹之模擬，所得成形壓力與鼓脹高度關係之模擬結果將與實驗進行比較以驗證本文所提模式之適用性。
最後，將針對鋁合金管材，利用具有軸向進給之管材液壓成形試驗機台進行液壓鼓脹成形試驗以建立材料之成形極限圖。另外，以Hill的新降伏準則及塑性不安定判別式預測金屬材料之成形極限曲線。將理論所預測之成形極限曲線與實驗所量測之成形極限圖互相比較驗證。
本研究成果可做為模具設計時之依據外，所獲得之塑流應力與成形極限圖將可提供企業界進行模擬解析時之製程參數，以使模擬結果更為準確。

Tube hydroforming process is a relatively new technology compared to conventional manufacturing via stamping and welding. However there is not much knowledge available for the product or process designers. The objective of this study will determine the flow stress and forming limit diagram of tubular materials to discuss the formability of tubes.
Firstly, a mathematical model is proposed to examine the plastic deformation behavior of a thin-walled tube at different process parameters during the bulge hydroforming process without axial feeding. In the formulation of this mathematical model, an ellipsoidal surface and non-uniform thinning in the free bulged region and sticking friction between the tube and die are assumed. In the sticking friction mode, the elements after contact with the die do not move or slide. The effects of various forming parameters, such as the die entry radius, the bulge length, anisotropy, the initial thickness of the tube, etc., upon the forming pressures are discussed systematically.
Secondly, an analytical model combined with hydraulic bulge tests is proposed to evaluate the properties of tubular materials considering anisotropy effect. Annealed AA6011 aluminum tubes and SUS409 stainless steel tubes are used for the bulge test. The tube thickness and radius at the pole and the internal forming pressure are measured simultaneously during the bulge test. The anisotropic values are obtained from tensile tests. From above experimental data, the effective stress - effective strain relations can be derived by this analytical model. The finite element method is used to conduct the simulations of hydraulic bulge forming with the flow stresses obtained by the above-mentioned model. The analytical forming pressures versus bulge heights are compared with the experimental results to validate the approach proposed in this study.
Finally, this study also establishes the Forming Limit Diagram (FLD) of aluminum tubular material. An experimental system of tube hydroforming in which axial feed is applied to carry out the hydraulic bulge-forming test of the annealed aluminum alloy tubes. Furthermore, Hill’s new yield criterion is also used to predict the Forming Limit Curves of sheets. The predicted forming limit diagrams are compared with the experimental data.
The results of this study can provide useful knowledge for process design. In addition, the process parameters of flow stress and forming limit diagram obtained can improve the accuracy of the simulation results in industrial and academic fields.

目錄 I
圖目錄 IV
表目錄 VIII
符號說明 IX
中文摘要 XI
英文摘要 XII
第一章 緒論 1
1-1 前言 1
1-2 管材液壓成形之製程簡介 3
1-2-1 管材液壓成形之發展現況 3
1-2-2管材液壓成形之優缺點 4
1-2-3 管材液壓成形之應用 5
1-2-4管材液壓成形之影響因素 6
1-3 管材液壓成形之文獻回顧 8
1-4 本文之研究目的 16
1-5 本文之架構 19
第二章 管材液壓鼓脹成形之解析 25
2-1 解析模式之基本假設 25
2-1-1 座標系定義 26
2-1-2 基本塑性力學方程式 26
2-2 固著模式之建構 28
2-2-1幾何關係 28
2-2-2 極點厚度之求得 29
2-2-3 成形壓力之求得 30
2-3 反推塑流應力之模式建構 32
第三章 成形極限曲線之解析 39
3-1 基本假設 39
3-2 SWIFT擴散不穩定準則 40
3-3 HILL局部不穩定準則 42
3-4 HILL一般化新降伏準則 43
第四章 單軸拉伸試驗與鼓脹試驗 48
4-1 管材之單軸拉伸試驗 48
4-1-1 萬能拉伸試驗機 48
4-1-2拉伸試片之製作 49
4-1-3 異方向性r值之求得 49
4-1-4材料塑流應力之求得 50
4-2管材之液壓鼓脹試驗 51
4-2-1 實驗設備 52
4-2-2 試驗管材之準備 53
4-2-3 模具設計與製作 54
4-2-4 量測儀器說明 56
4-2-5 管材無軸向進給之鼓脹試驗步驟 58
4-3 管材之成形極限試驗 59
4-3-1負載路徑之決定 59
4-3-1 實驗設備 59
4-3-2 試驗管材之準備 60
4-3-3 模具之設計與製作 61
4-3-4 管材具有軸向進給之液壓鼓脹試驗步驟 63
第五章 解析、模擬及實驗結果與討論 85
5-1管材兩端固定之鼓脹成形 85
5-2 單軸拉伸試驗 87
5-2-1 異方向性r值之求得 87
5-2-2 單軸拉伸之塑流應力求得 87
5-3塑流應力之求得與驗證 88
5-3-1鼓脹試驗結果與討論 88
5-3-2 有限元素模擬與實驗值之比較 91
5-4 成形極限圖之建立 93
5-4-1 理論預測成形極限曲線 93
5-4-2 具有軸向進給之液壓成形試驗 94
5-4-3 解析結果與實驗值之比較 94
第六章 結論 123
6-1 管材無軸向進給之液壓鼓脹成形 123
6-2 雙軸應力態下之塑流應力 124
6-3 成形極限曲線之解析與實驗 124
參考文獻 126
作者簡介 136
發表著作 137

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