本研究針對中空正齒輪（Spur gear）及外周螺旋之實心型材進行解析與實驗之研究。中空正齒輪部分，首先提出一設計準則以決定影響擠製結果之加工參數。接著以有限元素分析進行鎂錠從分流孔、銲合室至模具軸承部之流動型態。由一系列之解析結果，找出分流道長度、進料口導角長、銲合室高度對齒牙之徑向充填率，並藉由田口法討論找出影響較大之參數。最後設計一較佳之模具尺寸，進行模擬以獲得成功之產品。螺旋實心型材部分，透過有限元素分析了解鎂錠在模具瓣圓之充填率，從模擬結果中挑選參數設計模具。
最後進行中空正齒輪及螺旋型材之熱間擠製實驗，由產品尺寸及擠製荷重大小之解析值與實驗值作比較，驗證解析模式之可行性。

This study is to analyze and test the extrusion process of a hollow spur gear and a solid helical product with magnesium alloy. In the hollow spur gear part, firstly, a design criterion to determine the forming parameters is proposed. Then, the Finite Element Analysis is used to simulate the flow pattern of the billet from separating channel, welding chamber to die bearing part. From a series of simulation results, the effect of separating channel length, mandrel entrance angle, welding chamber height, etc. on the radial filling ratio, welding pressure, extrusion load, etc. are found. By using the Taguchi Methods, we can find the most important parameters. Finally, a better die geometry is designed to obtain a sound product. In the helical product part, the Finite Element Analysis is used to get the understandings of radical filling ratio of magnesium alloy in the helical zone. Then, a better die geometry is designed from the results of analyses.
Finally, hot extrusion experiments of a hollow spur gear and a solid helical product are conducted. The experimental values of the extrusion load and the product’s dimension are compared with the analytic values to verify the validity of the analytic models.

謝誌 ii
摘要 xi
Abstract xii
第一章 緒論 1
1-1 前言 1
1-2鎂合金特性 2
1-3 擠製加工製程之簡介 2
1-4鎂合金擠製加工技術之影響參數 5
1-5文獻回顧 6
1-6 研究動機與論文架構 11
第二章 中空正齒輪擠製有限元素分析 13
2-1齒輪各部位名稱介紹 13
2-1-1齒輪公式介紹 14
2-1-2齒廓曲線之繪製 14
2-2鎂合金AZ31正齒輪擠製有限元素分析之模組建立 15
2-2-1 有限元素分析軟體DEFORM-3D簡介 15
2-2-2正齒輪之幾何尺寸與擠製模型建立 16
2-2-3分流孔、心軸與銲合室之設計 18
2-3 鎂合金AZ31正齒輪擠製之製程參數研究 20
2-3-1齒牙徑向之充填率 21
2-3-2 網格細化對齒牙徑向充填率及擠製力之影響 22
2-3-3 不同進料口圓半徑之擠製荷重 22
2-3-4 產品之溫度分佈 23
2-3-5模具桁架變形之探討 24
2-3-6 不同銲合高度下之銲合壓力 26
2-3-7 模具齒牙之彈性變形 27
2-3-8 綜合結果比較 27
2-4 以田口法討論模具較佳參數 29
2-4-1前言 29
2-4-2田口法之基本原理 29
2-5田口法之分析結果與討論 30
2-5-1直交表之模擬參數規劃 30
2-5-2模擬結果分析 32
第三章 螺旋型材擠製有限元素分析 35
3-1 鎂合金AZ31螺旋型材之參數與擠製模型建立 35
3-2 鎂合金AZ31螺旋材擠製之模擬參數設定 37
3-3 解析結果與討論 38
3-3-1 螺旋型材徑向之充填率 38
3-3-2 模具軸承部長度之充填率探討 39
3-3-3 改變入口尺寸對擠製荷重與充填率之影響 39
3-3-4 產品之溫度分佈 41
3-3-5 不同瓣數及矩形數對產品充填率之影響 41
3-3-6 擠製速度及初始鎂錠溫度對旋轉角度之探討 42
3-3-7 矩形螺旋之長（H）、寬（W）之探討 43
3-3-8 綜合結果討論 44
第四章 鎂合金熱間擠製實驗 46
4-1 實驗設備及流程 46
4-1-1 擠製機台簡介 47
4-1-2 擠製實驗步驟簡介 50
4-2 模具之設計與製作 52
4-2-1 中空正齒輪模具之設計與製作 52
4-2-2 實心螺旋型材模具之設計與製作 52
4-3 擠製實驗參數之設定 58
4-3-1中空正齒輪擠製實驗參數設定 58
4-3-2 實心螺旋型材擠製實驗參數設定 59
4-4 解析值與實驗值之比較 60
4-4-1 中空正齒輪擠製之解析值與實驗值比較 60
4-4-2 螺旋型材擠製之解析值與實驗值比較 63
第五章 結論 67
5-1 中空正齒輪擠製 67
5-2 螺旋型材擠製 68
5-3 未來展望 68
參考文獻 69

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