本研究以無模具之拉製成形概念，設計並製造一無模拉製成形雛形機，採用高週波加熱機為加熱源，以兩座伺服馬達直接驅動導螺桿，使加熱源與拉製平台產生相對移動，進行一系列管材成形實驗，並在加熱機台上安裝紅外線測熱器與冷卻系統，控制並監控溫度變化，從而探討不鏽鋼SUS304管材在不同相對速度比、拉製速度與加熱溫度下的成形性，目前已可穩定達成40％之斷面縮減率，拉製速度最快可達0.8mm/s。同時以有限元素軟體進行管材之成形性分析，將獲得之管材均勻性、幾何相似率與實驗值比較，以驗證解析模式之可行性。並透過模擬過程中管材之有效應力、溫度等分布情形之探討，了解管材於無模拉製成形過程之變形機制，以期提升管材之拉製速度，並提高斷面縮減率。

In this study, a dieless drawing prototype machine has been developed for tube or wire drawing forming. This dieless drawing machine used a high-frequency heating apparatus as the heating source and used stainless steel SUS304 tube as specimens. A series of experiments with different relative speed between heating source and drawing grip were conducted. The moving power is transformed by two servo-motor connecting with screws. Infrared thermoscope and cooling device are setting on the high-frequency heating apparatus to control the temperature of specimen. The forming stability between different relative speed ratio, drawing speed and heating temperature has been discussed. The maximum stable reduction of area obtained can reach over 40 percent , and the drawing speed can be reach to 0.8mm/s. FE analysis was also conducted to analyz the formability of the tube. Then the validity of the analytical model was verified by comparing the uniformity and similarity between FE analysis and experiment value. A series of FE simulation results were used to understand the distribution of true stress and temperature in tube dieless drawing process, tryingand to improve the drawing speed and the reduction of area.

謝 誌.............................................................. ii
摘 要.......................................................... iii
Abstract ........................................................... iv
目 錄............................................................... v
圖目錄........................................................... viii
表目錄............................................................. xi
符號說明.......................................................... xii
第一章 緒論......................................................... 1
1-1 前言........................................................ 1
1-2 拉製成形技術之簡介.......................................... 2
1-2-1 有模拉製法............................................ 2
1-2-2 無模拉製法............................................ 2
1-2-3 影響無模拉製法之參數.................................. 3
1-2-4 金屬材料拉製可能產生之缺陷............................ 4
1-3 拉製成形之應用實例.......................................... 4
1-4 拉製成形之文獻回顧.......................................... 6
1-4-1 理論解析之文獻探討.................................... 6
1-4-2 實驗之文獻探討........................................ 6
1-4-3 有限元素模擬之文獻探討................................ 9
1-5 本文目的與架構............................................. 10
第二章 高週波無模拉製成形雛形機之設計.............................. 11
2-1 無模拉製成形雛形機之目的................................... 11
2-2 高週波無模拉製成形雛形機簡介............................... 11
2-2-1 機台支撐機構......................................... 12
2-2-2 加熱暨冷卻系統....................................... 15
2-2-3 傳動系統............................................. 18
2-3 無模拉製成形雛形機之控制系統............................... 19
2-3-1 控制系統之硬體介紹................................... 19
2-3-2 PLC 硬體簡介......................................... 21
2-4 拉製成形雛形機人機觸控頁面介紹............................. 22
2-4-1 手動與自動模式頁..................................... 22
2-4-2 參數監控模式頁....................................... 22
2-4-3 DI/DO 監控頁與歷史警報頁............................. 23
2-4-4 曲線圖............................................... 23
2-5 PLC 與人機控制的整合....................................... 27
2-6 機台規格與運轉機制......................................... 29
第三章 無模拉製成形實驗............................................ 31
3-1 無模拉製成形之變形機制..................................... 31
3-1-1 斷面縮減率之估算與幾何相似定理....................... 31
3-1-2 應變率與斷面縮減率之關係............................. 33
3-1-3 拉製實驗流程簡介..................................... 34
3-2 不鏽鋼SUS304 管材之成形性實驗.............................. 35
3-2-1 不同相對速度比之實驗結果............................. 36
3-2-2 不同拉製速度之實驗結果............................... 38
3-2-3 有限元素模擬與實驗值之比較........................... 39
3-3 實驗過程之不穩定與失敗現象................................. 41
第四章 無模管材拉製有限元素分析.................................... 44
4-1 解析模式之建立............................................. 44
4-2 材料塑流應力............................................... 46
4-3 解析結果與討論............................................. 53
4-3-1 解析範圍與管材成形機制............................... 53
4-3-2 拉製過程之應力分佈情形............................... 59
4-3-3 拉製過程之溫度分佈情形............................... 61
第五章 結論........................................................ 63
5-1 研究成果概要............................................... 63
5-1-1 實驗設備............................................. 63
5-1-2 成形性實驗........................................... 63
5-1-3 有限元素模擬......................................... 64
5-2 今後研究課題............................................... 65
參考文獻........................................................... 66
附錄 PLC 與人機系統之軟體控制說明.................................... I

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