以反應曲面法建立旋鍛製程之菇狀預測模型｜國立中央大學博碩士論文系統

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研究生：	田賀文 Her-wen Tian
論文名稱：	以反應曲面法建立旋鍛製程之菇狀預測模型
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：	2013
畢業學年度：	101
語文別：	中文
論文頁數：	110
中文關鍵詞：	旋鍛、傘形齒輪、菇狀、反應曲面法
外文關鍵詞：	rotary forging, bevel gears, mushroom shape, response surface methodology
相關次數：	點閱：14 下載：0
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在塑性變形中旋鍛製程為常用來製造傘形齒輪的加工方法，由Deng [16]等人文獻中發現，旋鍛製程所產生的菇狀大小與傘形齒輪的節錐角的差異多寡會影響鍛造的填充性與加工成形力。故本文利用Lin 與 Han [14]所指出影響菇狀大小的三個因子(沖頭傾斜角、旋轉進幾率、高寬比)做不同搭配的有限元素模擬，來求得菇狀大小，進而使用反應曲面法來做進一步的簡化，求得適合的回歸模型，以利減少加工傘形齒輪上的不良率。

Cold rotary forging is a common machining methodology to manufacture the bevel gears by plastic deformation. Deng et al. [16] observed that the size of the mushroom shape and the difference of the pitch-cone angle influence on the ability of fulfilling and the forging force. The finite element simulations could be set by the three following factors affecting the mushroom shape by Lin and Han [14]: (1) tilt angle of upper die (2) feed rate of rotary (3) ratio of height and width. The estimations of the mushroom shape by the different collocations of the above factors could be inducted by response surface methodology to get the proper mathematical model. It helps to reduce the defective rate of the manufacturing of the bevel gears.

摘要                                             i
Abstract                                        ii
致謝                                            iii
目錄                                             iv
表目錄                                          vii
圖目錄                                         viii
第一章    緒論                                          1
1-1     前言                                                 1
1-2     文獻回顧                                             2
1-3     研究動機與論文架構                                   5
第二章    MARC有限元素軟體介紹                          6 
2-1 MARC架構                                             6
2-1-1 有限元素求解程序                                 6
2-1-2 界面功能簡介                                     8
2-2 MARC前處理系統定義                                   9
  2-2-1 材料性質定義                                     9
  2-2-2 接觸定義                                        10
  2-2-3 網格重新劃分與自適應技術                        11
  2-2-4 摩擦效應定義                                    11
2-3 MARC分析求解技術定義                                12
  2-3-1 參考座標系統                                    12
  2-3-2 非線性代數方程組疊代求解方法                    13 
  2-3-3 收斂性判斷依據                                  14
  2-3-4 元素技術                                        15
2-4 MARC應用於旋鍛製程步驟                             16
  2-4-1建模步驟                                       16 
  2-4-2材料參數設定                                   16
  2-4-3模型控制條件                                   16 
  2-4-4收斂設定                                       17   
  2-4-5 JOBS分析工作設定                              17
  2-4-6 MARC結果顯示                                  17 
第三章    反應曲面法與實驗設計                           18
3-1 反應曲面法                                         18
3-2 基本原理                                            19
3-3 採用實驗設計法設計參數                              22
第四章    結果與討論                               24
4-1 旋鍛成形模擬驗證結果                                24
  4-1-1 旋鍛幾何變形                                    24
  4-1-2 旋鍛成形力量                                    24
  4-1-3 接觸面積之角度                                  25
4-2 MARC有限元素軟體結果                            25
  4-2-1MARC旋鍛加工過程菇狀變化                      25
  4-2-2 MARC旋鍛加工過程θ角變化                         26
4-3 各因子與菇狀反應的影響                           26
  4-3-1 γ傾斜角與菇狀                                  26
  4-3-2 S進給量與菇狀                                   27
  4-3-3 H/D高寬比與菇狀                                 28
4-4 反應曲面法回歸結果                                 28
  4-4-1 因變數變換                                     29
  4-4-2 自變數變換                                     30
  4-4-3 模型殘差分析                                   32
  4-4-4模型檢驗點驗證                                  35  
  4-4-5 比較菇狀之最佳模型                             35   
第五章    結論與建議                                     37
5-1 結論                                                 37
5-2 建議                                                 38   
參考文獻                                         39
附錄一                                           42
附錄二                                           43
附錄三                                           44
附錄四                                           45
附錄五                                           48

                                

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