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研究生： 陳煬智
Yang-Zi Chen
論文名稱： 有限元素法與反應曲面法對旋轉鍛造萬向接頭之最佳化分析
指導教授： 葉維磬
Wei-Ching Yeh
口試委員:
學位類別： 碩士
Master
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2019
畢業學年度： 107
語文別： 中文
論文頁數： 138
中文關鍵詞： 旋轉鍛造 、有限元素分析 、萬向接頭 、反應曲面法
外文關鍵詞： cold rotary forging, FEM, universal cross joint, Response Surface Methodology
相關次數： 點閱：16  下載：0 
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    • 本文利用有限元素軟體Deform-3D進行旋轉鍛造萬向接頭模擬分析，研究設計參數對填充率、最大成形力與應變均勻度的影響。本文之設計參數包含旋轉鍛造加工製程參數及對胚料預成形之參數設計等四個因子。胚料預成形設計參數包含胚料高度H和胚料上端面半徑R；旋轉鍛造加工製程參數包含上模具傾斜角γ以及下模每轉進給率S。
    首先經由中心點實驗確定適用二階模型迴歸，再透過最陡坡度法選定較佳的中心點，最終採用適合建構二階反應曲面之Box-Behnken四因子三水準的設計建立共25組模擬，並使用統計軟體Minitab依Deform-3D有限元素分析的結果進行迴歸分析，透過迴歸分析建立二階多項式預測模型。
    將本文所建立的品質特性預測方程式與有限元素模擬的結果進行驗證，其結果顯示預測模型具有精確度。並以Minitab求得填充率望大，成形力望小時之最佳化解,再透過模擬進行驗證確定最佳化結果的精確性。

    For this study, using a FE model by a software named Deform-3D on cold rotary forging of a universal cross joint. The purpose is to realize that the influence of design factors about filling rate, maximum forging load and equivalent strain uniformity.
    The four factors in the design include the work-piece geometry and the rotary forging process parameters. The work-piece geometry such as workpiece height H, the diameter upon the workpiece R and the rotary forging process parameter such us the process parameter with feed amount of per revolution S, and inclination angle of the upper die γ.
    First, by the design of center point making sure that the model is suitable for second order regression. Through the steepest-descent method to find a better point to be new center point. Then the experiment adopts 25 groups of analysis with the Box-Behnken design. Using the Minitab software to do the regression analysis and develop the predicted equations.
    By doing so, it’s expected to using the FEM model and surface response methodology to find the optimum design of the maximum filling rate and the minimum forging load. In this paper, quality characteristics prediction equation established with the results of finite element simulations can verify the results that the prediction model with considerable accuracy.

    目錄 摘要 iv 目錄 vii 圖目錄 xi 表目錄 xv 符號說明 xvii 第一章 緒論 1 1-1前言 1 1-2文獻回顧 3 1-2-1 圓柱及圓環旋轉鍛造鍛粗加工 4 1-2-2 複雜幾何鍛件的旋轉鍛造加工 9 1-3 研究動機 13 第二章 基本理論 15 2-1旋轉鍛造成型原理 15 2-2 旋轉鍛造運動分析 18 2-3十字軸式萬向接頭模具建立 27 第三章 有限元素法與實驗設計法 32 3-1有限元素模擬 32 3-1-1有限元素法於塑性加工之應用 33 3-1-2有限元素法之力學模式及數值分析 34 3-2 Deform-3D有限元素軟體[46] 35 3-2-1軟體介紹 35 3-2-2 Deform-3D的使用流程 36 3-3模擬參數設定 38 3-3-1旋轉鍛造加工參數及材料性質 38 3-3-2有限元素網格建構與模擬收斂性探討 40 3-4反應曲面法(Response Surface Methodology，RSM) [47] 45 3-4-1實驗設計 45 3-4-2迴歸分析基本理論 45 3-4-3模擬實驗因子與水準 48 3-4-4中心點實驗與參數優化 49 3-4-5 Box-Behnken實驗設計 58 第四章 結果與討論 61 4-1模擬驗證 61 4-2旋轉鍛造萬向接頭模擬結果 63 4-2-1旋轉鍛造萬向接頭之軸向成形力 67 4-2-2旋轉鍛造萬向接頭之填充率 68 4-2-3旋轉鍛造萬向接頭之應變均勻度 69 4-2-4旋轉鍛造萬向接頭實驗設計之結果 70 4-3模型建構 71 4-3-1填充率之迴歸分析 72 4-3-2成形力之迴歸分析 77 4-3-3應變均勻度之迴歸分析 81 4-3-4模型檢驗 85 4-4旋轉鍛造萬向接頭之最佳化分析 87 4-4-1模擬實驗最佳化 87 4-5品質因子對品質特性之效應 88 4-5-1品質因子對填充率之效應 89 4-5-2品質因子對成形力之效應 93 4-5-3品質因子對應變均勻度之效應 98 第五章 結論與建議 103 5-1結論 103 5-2建議 104 參考文獻 105 附錄A 112 附錄B 115

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