管件液壓成形技術是一種相對新穎的結構輕量化加工技術，其中異形截面管件的液壓成形製程近年來被廣泛使用於汽車工業，如儀表板、散熱器、引擎、水箱與風扇等各類支架。而異形截面管件也應用於我們的日常生活中的各種小零件。
本文欲以液壓成形與沖壓製程製造一兩端各為矩形端面與圓形端面的異形管，選用的材料是高強度車用鋼SPFC590Y，將SPFC590Y 鋼板拿去裁切試片，進行單軸拉伸試驗，獲取該材料於室溫的塑流應力。首先將以有限元素套裝軟體DYNAFORM分析鋼管在液壓鼓脹成形與沖壓製程的塑性變形過程，比較不同負載路徑下產品的成形性與厚度分布，選擇適當的負載路徑，得到一沒有缺陷且厚度均勻分布的產品。最後利用自行設計的矩形堵頭，配合模具作動與適當的內壓力路徑，進行有縫鋼管管件液壓成形實驗，將實驗成品的厚度分布與外型與模擬結果進行比較，驗證有限元素軟體的適用性。

Tube hydroforming is a relatively new manufacturing approach for producing lightweight metal structure components. Profile tubes, which have different shape at different cross sections, are widely used in automotive parts, such as the supporting frames for dashboard, engine radiator, water tank and fan, etc. Many profile tubes can also be found in our daily life.
In this study, a profile tube with rectangular and circular cross-sections at the both ends is formed by hydroforming and crushing processes. Carbon steel of SPFC590Y is used as the tube material. The flow stress of SPFC590Y steel tubes at room temperature is obtained by tensile tests. At first, a finite element simulation software DYNAFORM is adopted to analyze the plastic deformation of the steel tubes during the hydroforming and crushing processes. Then, effects of various loading paths on the formability and thickness distribution of the products are discussed. An appropriate loading schedule is designed and the corresponding loading path is found out to obtain products without defects and uniform thickness distribution. Finally, a profile die and rectangular punches are designed, and experiments of hydroforming and crushing processes using ERW steel tubes are conducted. Experimental results of the thickness distributions and shapes of the products are compared with the simulation results to verify the designed loading schedule and the validity 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 ix
表目錄 xiii
符號說明 xiv
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 管材液壓成形製程之優缺點 3
1-2-2 管材液壓成形之應用實例 4
1-2-3 管材液壓成形之影響因素 5
1-3 文獻回顧 8
1-3-1 管件液壓成形解析相關文獻 8
1-3-2 管件液壓成形技術相關文獻 9
1-4 研究動機與目的 10
1-5 論文架構與研究流程 10
第二章 異形截面管材之液壓成形模具設計 12
2-1 前言 12
2-2 設計概念與原理 12
2-2-1 成形內壓力分析 12
2-2-2 管材成形前後矩形和圓形區域的周長計算 14
2-3 完成之模具形狀及尺寸 15
2-3-1 初期模擬分析用 15
2-3-2 兩端面圓管 15
2-3-3 兩端面矩形管 16
2-4 中碳鋼管SPFC590Y 之單軸拉伸試驗 18
2-4-1 單軸拉伸速率 18
2-4-2 拉伸試片之規格與製作 18
2-4-3 材料塑流應力之計算 19
2-4-4 拉伸試驗之結果 20
第三章 異形截面管材之液壓成形有限元素分析 22
3-1 前言 22
3-2 DYNAFORM與LS-DYNA求解核心介紹 22
3-3 模擬分析之基本假設 23
3-4 異形截面管材之液壓成形解析 23
3-4-1 幾何模型建立 23
3-4-2 參數設定 24
3-4-3 成形負載路徑之探討 25
3-4-4 厚度分布之探討 26
3-5 兩端面圓管之液壓成形解析 28
3-5-1 幾何模型建立 29
3-5-2 參數設定 29
3-5-3 成形負載路徑之探討 30
3-5-4 厚度分布之探討 31
3-5-5 圓角半徑的探討 34
3-5-6 成形負載之探討 35
3-6 兩端面矩形管之液壓成形解析 36
3-6-1 幾何模型建立 36
3-6-2 參數設定 37
3-6-3 成形負載路徑之探討 37
3-6-4 厚度分布之探討 38
3-6-5 圓角半徑的探討 41
3-6-6 成形負載之探討 42
3-7 DC04 應用於實驗模具之液壓成形解析 43
3-7-1 幾何模型建立 43
3-7-2 參數設定 44
3-7-3 成形負載路徑之探討 45
3-7-4 厚度分布之探討 46
第四章使用DC04有縫鋼管之異形管件液壓成形實驗 48
4-1 實驗目的 48
4-2模具配置與設計 48
4-3 實驗設備 54
4-4實驗步驟 55
4-5 實驗結果與解析結果之比較 56
4-5-1 實驗成品外觀 56
4-5-2 厚度分布與模擬結果比較 57
4-5-3 圓角半徑 59
第五章 結論 62
5-1 異形截面管材之液壓成形有限元素分析 62
5-2 使用DC04 有縫鋼管之異形管件液壓成形實驗 62
5-3 今後研究之課題 63
參考文獻 64

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