管件液壓成形技術為一種相對新的技術應用在結構輕量化上。隨著環保意識提高，在航太工業、汽車工業利用質量輕且堅固的製造技術以達到節省能源的效果，並且使得液壓成形技術能夠有更多元的應用。本研究專注於大鼓脹變形與可移動式模具間之負載曲線的討論，並以油槍管做為討論之成品。而油槍管外形的特性為非對稱且有一大鼓脹之區域的成形結構，在製作過程中為了避免缺陷產生，如挫曲、皺褶與破裂的情況利用可移動式模具作為鼓脹區域的控制以達到成品厚度較為均一的情況。利用DYNAFORM與LS-DYNA進行有限元素分析，與材料A6061-O之材料進行參數之討論，包括主推桿進給量、次推桿進給量、可移動式模具進給量和內壓力路徑對不同移動模具外形於成品厚度之影響。

Tube hydroforming is a relatively new manufacturing approach for producing lightweight metal structure components. Because of the increasing environmental awareness, using lighter and stronger componments are required to achieve energy-saving, and makes hydroforming technology have more applications in industrial manufacturing. In this study, a refueling tube applied in the car is selected as the finished product. It is focused on the discussion of large-expansion ratio tube hydroforming with movable die and loading path. The shape of refueling tube has features of large-expansion ratio and asymmetric structure. In the forming process, in order to avoid the occurrence of defects, such as buckling, wrinkling and crack, a movable die is used to control the forming area to make the thickness more uniform at the finished product. Finite element code LS-DYNA and DYNAFORM is used to analyze. The plastic deformation of the material A6061-O is used. The effect of primary punch axial feeding, secondary punch axial feeding, movable die feeding and internal pressure on the thickness of the product are discussed.

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 xiv
第一章 緒論 3
1.1 前言 3
1.2 管件液壓成形技術簡介與應用 6
1.2.1 管件液壓成形理論與影響因子 7
1.2.2 管件液壓成形之優缺點 12
1.2.3 管件液壓成形技術應用 13
1.2.4 可移動模具應用於管件液壓成形介紹 14
1.3 文獻回顧 15
1.3.1 管件液壓成形技術相關文獻 15
1.3.2 管件液壓成形解析相關文獻 16
1.4 研究動機與目的 19
1.5 論文架構與研究流程 20
第二章 大鼓脹管件液壓成形之有限元素分析 22
2.1 前言 22
2.2 DYNAFORM與LS-DYNA求解核心簡介 22
2.3 材料機械性質 24
2.3.1 鋁合金A6061單軸拉伸試驗 24
2.3.2 鋁合金A6061塑流應力計算 26
2.4 大鼓脹液壓成形設計概念 31
2.4.1 大鼓脹液壓成形設計概念 33
2.4.2 對稱大鼓脹液壓成形模具 35
2.4.3 非對稱大鼓脹液壓成形模具 37
2.5 對稱大鼓脹管件液壓成形模擬解析 38
2.5.1 幾何模型建立 38
2.5.2 參數設定 49
2.5.3 成形負載路徑探討與厚度分布圖、成形極限圖探討 50
2.6 非對稱大鼓脹管件液壓成形模擬解析 63
2.6.1 幾何模型建立 63
2.6.2 參數設定 69
2.6.3 成形負載路徑探討與厚度分布圖、成形極限圖探討 70
2.6.4 歩階成形負載曲線對管件厚度之影響 78
第三章 非對稱大鼓脹管件液壓成形實驗 82
3.1 實驗目的 82
3.2 實驗管材使用與設備模具配置 82
3.2.1 實驗管材使用 82
3.2.2 實驗設備配置 84
3.2.3 實驗模具配置 86
3.3 實驗步驟 88
3.4 實驗結果討論 90
3.4.1 實驗成品外觀 90
3.4.2 實驗之負載曲線與模擬之負載曲線比較 91
第四章 結論 93
4.1 對稱大鼓脹管件液壓成形之模擬 93
4.2 非對稱大鼓脹管件液壓成形之模擬 93
4.3 非對稱大鼓脹管件液壓成形實驗 94
4.4 今後研究課題 94
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