管材液壓成形技術已廣泛地被應用於工業上各零組件之製造。在成形過程中負載路徑，即內壓力、軸向進給量與背向進給對時間之關係，對於成形的結果有決定性的影響。而有限元素模擬常被用來模擬不同負載路徑下之成形結果，以降低實際試模所需的花費。本文以具有背向進給之T形與Y形管件液壓成形為對象，以有限元素軟體LS-DYNA 3D結合控制副程式來進行自適性模擬。由本文之多階段控制方式所獲得之管厚分佈較直線控制獲得之厚度分佈來得均勻。由解析值與實驗值之比較，證實此法之可用性。

The tube hydro-forming (THF) is an innovative manufacturing process which is used to manufacture many industrial components widely. The success of THF is largely dependent on the selection of the loading paths: internal pressure versus time, axial feeding versus time and counter punch (CP) versus time. The finite element analysis is used to simulate the forming result of different loading paths and reduce the cost of die-testing. This paper presents the forming of T-branches and T-branches components with CP. These paper has developed an adaptive simulation algorithm by combining FEM code LS-DYNA 3D with controller subroutine to get ideal bulging height and uniform thickness of the formed tube with multi-stages. Discuss influence under different parameters of process. The results are compared with experimental results to validate accuracy by this adaptive control methods.

摘要 I
Abstract II
目錄 III
圖目錄 VI
表目錄 XI
符號說明 XII
第一章 緒論 1
1-1 前言 1
1-2 管材液壓成形技術簡介 2
1-3 文獻回顧 3
1-4研究動機與目的 6
1-5論文架構 6
第二章 有限元素模擬簡介 10
2-2 基礎理論 10
2-2-1 Implicit Method & Explicit Method 10
2-2-2 Hughes-Liu Shell 12
2-2-3中心差分法(Central Difference Method) 16
2-2-4 時間步驟(Time Step) 16
2-3 模擬基本架構 17
2-4 幾何模型建立 18
2-5 前處理 21
2-5-1 假設條件 21
2-5-2 網格分割 22
2-5-3 材料性質 24
2-5-4 邊界條件 24
2-6 控制程式架構 26
2-6-1 I/O模組 27
2-6-2運算模組 28
2-6-3 連接器 28
2-6-4 重啟動(restart) 29
第三章 自適性控制策略 33
3-1 前言 33
3-2 皺褶偵測與控制 33
3-3 薄化偵測與控制 34
3-4 接觸長度偵測與控制 34
3-5 控制流程 35
3-5-1 T形鼓脹進給(自由鼓脹)之控制策略 35
3-5-2 T形鼓脹進給(含背向力)之控制策略 36
3-5-3 Y形鼓脹進給(含背向力)之控制策略 40
第四章 模擬結果與討論 52
4-1 前言 52
4-2 T形鼓脹進給(自由鼓脹)分析結果 52
4-2-1 初始厚度對成形結果之影響 52
4-2-2摩擦力與成形之關係 53
4-2-3 結果與討論 53
4-3 T形鼓脹進給(背向進給)分析結果 54
4-3-1 初始厚度對成形結果之影響 54
4-3-2 摩擦力與成形結果之關係 55
4-3-3 自由鼓脹與具有背向進給之比較 56
4-3-4 薄化率與成形高度對負載路徑之影響 57
4-3-5 結果與討論 58
4-4 Y形鼓脹進給(背向進給)分析結果 59
第五章 液壓成形實驗 82
5-1 實驗目的 82
5-2 實驗設備 82
5-3 實驗結果 82
5-3-1 解析例與實驗值之比較 83
第六章 結論 92
6-1 研究成果之概要 92
6-2 今後研究之課題 92
參考文獻 94
附錄A 使用軟體介紹 98
附錄B 交叉模與平面模之規範 101
附錄C LS-DYNA關鍵檔 106
附錄D LS-DYNA體積不變之證明 111

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