精密型材廣泛用於3C 產品、電子儀器、通信設施、精密機械、汽車工業等方面，這類型材的特點是外形尺寸小或尺寸公差要求嚴格。由於異形材之擠製加工時，初胚在模穴內的塑性變形變得較為複雜，且初胚之溫度分佈、模具之彈性變形及導流板之設計等，皆會影響最後產品之尺寸與精度。本文將以有限元素軟體DEFORM 3D 針對非對稱鋁合金異形材夾片(Clip)及外框(Housing)之3C 產品之擠製加工，進行初胚於模穴內塑流型態之解析，針對所設計之模具在擠製過程中之成品形狀、應力、應變、擠製力、溫度、產品的變形機制等進行一系列探討。以此改進模具之設計。並綜合探討溫度及模具變形對擠製產品形狀及尺寸之影響，以供製程設計與模具設計參考之用。另外，亦進行擠製實驗，由溫度、產品尺寸、擠製力之比較，驗證模具設計結果之正確性。

Extruded products with precision shape have been used widely to 3C products, electronic equipment, communicatory installation, precision instrument, automobile industry. The tolerance for this kind of asymmetric products with small size is strictly required. During extrusion, the plastic flow of the billet inside the die cavity is complicated. The temperature distribution of the billet, the elastic deformation of the die, and the design of the flow guide affect the final dimension of the product. This paper uses the finite element code “DEFORM 3D” to simulate the plastic flow of the billet inside the die cavity and the stress, strain, temperature distributions of the die during extrusion of a 3C product, Clip and Housing. From the simulation results, a die design guideline is proposed and the temperature, stress, strain distributions are discussed systematically. Furthermore, extrusion experiments are conducted. From the comparisons of the temperature at the die exit, the product sizes and the extrusion force, the validity of the die design rule is verified.

目錄……………………………………………………………………………III
表目錄……………………………………………………………………………VI
圖目錄……………………………………………………………………………VII
第一章 緒論………………………………………………………………………1
1-1 前言…………………………………………………………………………1
1-2 擠製製程簡介……………………………………………………………2
1-3 模具設計原則……………………………………………………………4
1-4 文獻回顧…………………………………………………………………6
1-4-1 異型材擠製模具的設計及製程的模擬……………………………6
1-4-2 導流板的設計………………………………………………………7
1-4-3 軸承部的設計………………………………………………………8
1-4-4 空心材擠製…………………………………………………………8
1-5 研究目的…………………………………………………………………9
第二章 夾片擠製有限元素分析………………………………………………12
2-1 有限元素分析軟體DEFORM 3D 簡介…………………………………12
2-2 模擬參數的設定………………………………………………………13
2-3 模具之幾何尺寸說明…………………………………………………13
2-3-1 軸承長度與模穴尺寸(設計前) ……………………………………14
2-3-2 夾片之塑性流動特性………………………………………………15
2-3-3 軸承部之設計……………………………………………………16
2-3-4 導流模穴之設計…………………………………………………17
2-4 網格分佈與重要幾何尺寸之設定……………………………………18
2-5 擠製結果………………………………………………………………18
2-5-1 擠製成品…………………………………………………………18
2-5-2 負載衝程…………………………………………………………19
2-5-3 應力、應變…………………………………………………………20
2-5-4 溫度分佈…………………………………………………………20
2-6 夾片模具分析……………………………………………………………20
2-6-1 模具應力分佈………………………………………………………21
2-6-2 模具變形分析………………………………………………………21
2-6-3 擠製後產品尺寸與溫度的關係……………………………………22
第三章 外框擠製有限元素分析………………………………………………34
3-1 模擬參數的設定…………………………………………………………34
3-2 模具之幾何尺寸說明……………………………………………………34
3-3 軸承部之設計…………………………………………………………..34
3-4 分流孔與心軸之設計……………………………………………………35
3-4-1 縮模型模具設計……………………………………………………36
3-4-2 直模型模具設計…………………………………………………36
3-4-3 擴模型模具設計…………………………………………………37
3-5 網格分佈與重要幾何尺寸之設定………………………………………38
3-6 擠製結果…………………………………………………………………39
3-6-1 縮模型擠製結果……………………………………………………39
3-6-2 平模型擠製結果…………………………………………………40
3-6-3 擴模型擠製結果…………………………………………………40
3-7 外框模具分析……………………………………………………….......41
3-7-1 縮模型模具分析…………………………………………………42
3-7-2 平模型模具分析…………………………………………………43
3-7-3 擴模型模具分析…………………………………………………44
第四章 鋁材的熱間擠製實驗…………………………………………………73
4-1 模具的設計與製作………………………………………………………73
4-2 實驗設備與實驗步驟…………………………………………………73
4-3 夾片實驗結果與解析結果的比較……………………………………75
4-4 外框實驗結果與解析結果的比較……………………………………77
第五章 結論……………………………………………………………………91
5-1 研究成果概述……………………………………………………………91
參考文獻………………………………………………………………………93

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