鋁合金5182具有高比強度、電磁遮蔽性、抗蝕性佳及易回收等材料特性，經常應用於罐蓋材、車輛結構件及電子3C產品等領域。熱軋過程中板材應變及溫度顯著地影響微觀組織，進而改變產品的強度及成形性，為提升產品性能，必須掌握熱軋加工參數對板材應變及溫度之影響。過去雖然已有文獻研究應變及溫度對鋁合金5182靜態再結晶組織之影響，然而，並未詳細探討熱軋加工參數對鋁合金5182板材應變及溫度之影響。
本文是應用有限元素分析軟體DEFORM於鋁合金5182板材熱軋加工時之應變及溫度模擬，首先，為瞭解鋁合金5182在高溫成形時材料之塑流應力並且使其能應用於有限元素模擬，使用Gleeble熱機模擬試驗機進行圓柱壓縮試驗來獲得320oC至470oC且應變率0.01 s-1至30.0 s-1之鋁合金5182平均塑流應力，接著透過有限元素法來獲得平均塑流應力與材料塑流應力之關係，以此關係可知當考慮摩擦力之影響時平均塑流應力與材料塑流應力之間僅有2%~4%之誤差，最後以具有雙曲正弦函數之本構方程式來描述塑流應力並且使用最小平方法之運算來獲得本構方程式之參數，本構方程式之預測值與實驗值之間最大誤差約為10%以內。
接著，以改變摩擦係數、壓下率、入口板厚、工輥速度及界面熱傳係數等參數進行熱軋加工有限元素模擬，討論加工參數與邊界條件對軋延過程中板材溫度歷程變化之影響以及輥隙出口處板材等效應變分布與溫度分布，將模擬結果代入文獻提出之靜態再結晶組織變化的預測模型，討論軋延參數與邊界條件對靜態再結晶組織變化之影響。最後整理出軋延參數與邊界條件對板材應變、溫度及靜態再結晶組織之影響機制。
最後，以一系列軋延參數及邊界條件進行有限元素模擬，根據模擬結果及迴歸分析建立預測軋延力、前滑率、出口板材表面溫度、出口板材平均溫度及完軋後板材平衡溫度之經驗公式，接著以連續軋延時板材流動之原理結合預測軋延結果之經驗公式，建立一應用於鋁合金5182熱連軋製程軋延結果之預測模型。此預測模式適用之範圍如下：(1)工輥直徑為700至1000 mm；(2)入口板材厚度為5至50 mm；(3)壓下率為30至60%；(4)庫侖摩擦係數為0.15至0.40；(5)張力與平均變形阻抗之比值為0至0.4；(6)工輥速度為0.1至6.0 m/s；(7)入口板材溫度為320oC至450oC；(8)接觸界面熱傳係數為10至400 kW/m2∙oC。
本論文之研究成果及經驗公式可作為鋁合金5182熱軋製程設計之依據外，塑流應力預測模式亦可提供企業界應用於熱間加工製程之模擬解析，使其模擬結果更為精確。

Aluminum alloy 5182 (AA5182) has been widely used in beverage cans, automobile parts, computer, communication and consumer electronics (3C) products for excellent properties, such as high strength-to-weight ratio, electro-magnetic shielding, better corrosion resistance, and recyclable etc. The strain and temperature of the hot rolled strip affect the microstructure of material as well as change the strength and formability of the product. In order to improve the product performance, it is essential to understand the effect of process parameters during hot rolling on the strain and temperature of the strip. Several studies have been published to investigate the effects of strain and temperature on the recrystallization behavior of AA5182 strip during hot rolling. However, only a few studies published discussed the effects of process parameters on the strain and temperature distributions of AA5182 strip during hot rolling.
In this study, the finite element simulations of the strain and temperature distributions of AA5182 during hot rolling were carried out by using a commercial code DEFORM. Firstly, the cylindrical compression tests were performed to obtain the mean flow stress curves of AA5182 at strain rates of 0.01 s-1 to 30.0 s-1 under 320oC to 470oC by using Gleeble thermal-mechanical simulator for understanding the strength of material at elevated temperatures. The mean flow stress curves were applied to simulate the hot rolling of AA5182 strip. The relationships between the mean flow stress obtained by the cylindrical compression test and material flow stress were established by using the finite element simulations. It is known that the error between the mean flow stress and material flow stress is about 2% to 4% during the cylindrical compression test considering the effect of friction at the interface between the cylindrical and anvils. A hyperbolic-sine Arrhenius equation was used to characterize the flow stress curves of aluminum alloy 5182. The parameters of characterization equation were obtained by using experimental data and the least square method. The error between the prediction results obtained by the characterization equation and the experimental data is within 10%.
Secondly, the finite element simulations of hot rolling were carried out to investigate the effects of process parameters and boundary conditions involved reduction in thickness, entry thickness, rolling speed, coefficient of coulomb friction and interfacial heat transfer coefficient on temperature variation of the strip and distributions of strain and temperature in the thickness direction at the roll bite exit. The results of simulations were applied to the prediction model of static recrystallization behavior proposed by literature and discussed the effect of process parameters and boundary conditions mentioned above on static recrystallization behavior. The mechanisms about effects of process parameters and boundary conditions on strain, temperature, and static recrystallization behavior of the strip were proposed.
Finally, the empirical equations were established for predicting rolling force, forward slip ratio, surface temperature and average temperature of strip at the roll bite exit and balance temperature of the strip by regression analysis and simulation results. A prediction model for the rolling results of hot continuous rolling of AA 5182 was also proposed. The parameters applicable of the prediction model proposed are as follow: the work roll diameter is 700 to 1000 mm, the entry thickness 5 to 50 mm, the reduction in thickness 30% to 60%, the coefficient of coulomb friction 0.15 to 0.40, the ratio between tension and mean deformation resistance 0 to 0.4, the speed of work roll 0.1 to 6.0 m/s, the entry temperature 320oC to 450oC, the interfacial heat transfer coefficient 10 to 400 kW/m2∙oC.
The results of this study and the empirical equations proposed can provide useful knowledge for rolling pass schedule design during hot rolling process of AA 5182. In addition, flow stress characterization equation proposed can improve the accuracy of simulation results of hot forming processes in industrial and academic fields.

論文審定書 i
誌謝 ii
摘要 iii
英文摘要 v
總目錄 viii
表目錄 xii
圖目錄 xiv
符號說明 xx
第一章 緒論 1
1-1 前言 1
1-2 鋁合金熱軋製程簡介 2
1-2-1 生產流程 2
1-2-2 軋延設備 3
1-2-3 熱軋組織與性能變化 5
1-3 文獻回顧 6
1-3-1 塑流應力之研究 6
1-3-2 熱軋製程之研究 9
1-3-3 軋延結果預測之研究 11
1-4 本論文之研究方向 13
1-5 本論文之架構 15
第二章 板材熱軋加工之有限元素模型 24
2-1 有限元素法簡介 24
2-2 有限元素分析軟體DEFORM 25
2-2-1 基本理論 25
2-2-2 軟體架構 29
2-2-3 分析模式 29
2-2-4 材料模式 29
2-3 板材熱軋之有限元素模型 31
2-3-1 板材軋延之原理 31
2-3-2 板材溫度變化之分析模式 31
2-3-3 有限元素模型 33
2-4 有限元素模擬之進行流程 37
第三章 鋁合金5182之塑流應力 45
3-1 圓柱壓縮試驗 46
3-1-1 Gleeble熱機模擬試驗機 46
3-1-2 實驗規劃及流程 47
3-1-3 實驗結果 49
3-2 圓環壓縮試驗 50
3-2-1 實驗規劃及流程 51
3-2-2 摩擦係數校正曲線 52
3-3 塑流應力之修正 53
3-3-1 摩擦力之修正 53
3-3-1-1切片法 54
3-3-1-2有限元素法 59
3-3-2 變形熱之修正 63
3-4 塑流應力預測模式 64
3-4-1 塑流應力之本構方程式 64
3-4-2 最小平方法原理 65
3-4-3 最小平方法運算流程 67
3-4-4 塑流應力預測模式 69
3-4-5 塑流應力預測模式適用範圍之探討 70
3-4-5-1 Takuda塑流應力預測模式 71
3-4-5-2 預測模式之比較 72
3-5 結論 74
第四章 鋁合金5182板材熱軋加工之有限元素模擬 103
4-1 再結晶組織與軋延參數之關係 104
4-1-1 Avrami方程式 104
4-1-2 再結晶組織變化之數學模型 105
4-2 熱軋加工參數對板材溫度歷程之影響 106
4-3 熱軋加工參數對板材變形及再結晶組織之影響 111
4-4 鋁合金5182板材之熱軋實驗 117
4-4-1 實驗流程 117
4-4-2 實驗結果與有限元素模擬結果之比較 118
4-5 結論 120
第五章 鋁合金5182板材熱軋加工之軋延結果預測模式 162
5-1 軋延結果預測模式 164
5-1-1 研究方法 164
5-1-2 熱軋加工參數之規劃 164
5-1-3 有限元素模擬之數據擷取 167
5-1-4 軋延結果預測模式之建立 168
5-1-5 軋延結果預測模式之整合 172
5-1-6 板材平衡溫度之預測模式 177
5-2 軋延結果預測模式於熱連軋製程之應用 179
5-2-1 連續軋延時板材流動之原理 180
5-2-2 鋁合金5182板材熱連軋製程之軋延結果預測模型 180
5-3 結論 183
第六章 總結與未來展望 209
6-1 總結 209
6-2 未來展望 212
參考文獻 213
作者簡介及發表著作 224

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