本論文透過有限元素軟體Deform-3D進行旋轉鍛造傘形齒輪模擬分析，研究上模具運動路徑對填充率與應變均勻度的影響。本文之設計參數包含對胚料預成形之參數設計及旋轉鍛造加工製程參數等六個因子。胚料預成形設計參數包含體積V、胚料下端高度h_1、胚料上端直徑d_1以及胚料下端直徑d_2；旋轉鍛造加工製程參數包含下模每轉進給率S以及上模具傾斜角γ。實驗設計採用適合建構二階反應曲面之Box-Behnken 6因子3水準的設計建立共49組模擬，使用統計軟體Minitab依Deform-3D有限元素分析的結果進行回歸分析，以建立旋轉鍛造之填充率及應變均勻度的預測模型，進而探討各因子對填充率及應變均勻度的影響以及最佳設計參數之水準。本文所建立的填充率及應變均勻度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相當的準確度。

關鍵字:旋轉鍛造、有限元素分析、傘形齒輪

An ideal FE model of cold rotary forging of a spur bevel gear is developed under the Deform-3D software and the upper die motion path on filling rate and equivalent strain uniformity are in this study.
The six factors in the design include the work-piece geometry and the rotary forging process parameters. The work-piece geometry such us piece volume V, Lower height〖 h〗_1, the diameter of the upper and lower diameter〖 d〗_1 〖、d〗_2 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.The experiment adopts 49 groups of analogs with the Box-Behnken design. Use the Minitab software to do the regression analysis and develop the predicted equations. By doing so, it’s excepted using the FEM model and surface response methodology to find the optimum design of the filling rate and equivalent strain uniformity .
In this paper filling rate and strain uniformity prediction equation established with the results of finite element simulations to verify the results show the prediction model with considerable accuracy.

Keywords: cold rotary forging, FEM, spur bevel gear

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