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研究生： 張智泓
Chih-hung Chang
論文名稱： 民航客機機翼前緣整流罩之超速塑成型製程研究
Superplastic Forming Processes Research of Commercial Airliner Wing’s Leading Edge Fairing Covers
指導教授： 李雄
Shyong Lee
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
畢業學年度： 99
語文別： 中文
論文頁數： 161
中文關鍵詞： 整流罩 、壓力-時間成形曲線 、超塑成形 、5083鋁合金
外文關鍵詞： Pressure-time curve, Aluminum alloy 5083, Superplastic forming, Fairing cover
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    • 常見的超塑性製程多以平板直接吹氣成形，且成形形狀都呈簡易對稱之形狀、少有曲面複雜且幾何外型不對稱之實際工件製作，本論文即以飛機製造業使用之鋁合金蒙皮零件“機翼前緣整流罩”為超塑成形之研究主角，且在執行超塑成形前將先加入材料的折彎預成形加工，過程中使用5083鋁合金並應用計算之壓力-時間成形曲線來作超塑成形、除了折彎預成形製程外、同時嘗試以5182鋁合金來執行預成形材折彎後的室溫引伸製程之試製與評估，材料的折彎預成形目的是為了使板材在尚未執行超塑性製程前便已縮短材料與成形模具的距離，並使之更容易完成超塑成形，其中若再加入引伸加工之製程目的也是用來縮減成形距離與成形時間，不同類型的折彎預成形形狀，使得材料在執行超塑成形時將有不同的流動方式，材料在高溫環境中的變形趨勢，將直接影響材料與模具模壁的接觸模式，為此本實驗藉先分析一般平板工件的成形趨勢、材料從平板的變形曲線變化趨勢至折彎預成形板材的曲線變形趨勢，由淺入深，以此要領來分析整流罩的超塑成性形研究，目的更在於完整流罩工件(亦稱“全尺寸工件”)的吹製。

    Superplastic Forming (SPF) Processes usually uses plates to produce simple and symmetrical shapes, however, complicated and non-symmetrical shapes are seldom produced using SPF.
    This thesis focuses on using SPF to manufacture the aluminum ”Fairing Cover” used on an actual commercial airliner. The pressure-time curves were calculated for commencing SPF process. The materials used for the research was 5083 aluminum alloys. The processed plate undergoes a pre-form bending process before SPF in order to shorten the distance between the material and the mold. In addition, 5182 aluminum alloys was used to evaluate the feasibility of room temperature drawing of the bent pre-form to further shorten the material’s distance to the mold and decrease SPF processing time.
    Different pre-form shapes have different flow patterns and the pre-form shapes directly influence how the material contacts the mold during high temperature forming. This research analyzes the deforming trend from plate and from the bent pre-form, in hopes of completing the full size fairing cover component using SPF.

    摘要..................................................i Abstract..............................................ii 目錄..................................................iii 圖目錄................................................viii 表目錄................................................xx 符號說明..............................................xxi 第一章:緒論...............................................1 1-1.前言.................................................1 1-2.超塑性成形概論.......................................2 1-2-1.超塑性............................................2 1-2-2.組織超塑性........................................3 1-2-3.環境超塑性........................................3 1-2-4.超塑性的實用意義..................................4 1-3.一般超塑成形製程.....................................5 1-3-1.一般超塑性與與傳統加工方法比較....................5 1-3-2.一般超塑性亦有以下缺點............................6 1-4.全尺寸工件之超塑成形製程.............................7 1-4-1.全尺寸超塑性與一般超塑性比較......................9 1-4-2.全尺寸超塑性與一般超塑性比較有以下缺點............9 1-5.研究目標............................................10 第二章:分析理論及實驗設備................................16 2-1.成型理論............................................16 2-1-1.超塑成形組成方程式...............................16 2-1-2.應變及應變速率計算理論...........................17 2-2.實驗設備............................................20 2-3.實驗材料............................................23 2-4.實際試驗製程介紹....................................24 第三章:長方形開口盒之超塑成型............................32 3-1.長方形開口盒之幾何形狀..............................32 3-2.長方形開口盒之成形模具幾何形狀與材料變化趨勢探討....33 3-3.長方形開口盒之壓力-時間成形曲線(Pressure-Time Curve)35 3-4.長方形開口盒之超塑成型參數..........................37 3-4-1.使用之成形應變速率...............................37 3-4-2.成形溫度.........................................37 第四章:全尺寸工件之超塑成型..............................42 4-1.全尺寸工件之幾何形狀................................42 4-2.全尺寸工件多道次製程研擬............................44 4-2-1.全尺寸工件多種類預折彎模具分析概論..............44 4-2-2.折彎預成形+超塑成形之方法.......................46 4-2-3.折彎預成形+引伸沖壓+超塑成形之方法..............46 4-2-4.引伸沖壓預成形+超塑成形之構想...................47 4-3.全尺寸工件引伸模具種類與介紹.......................49 4-3-1.熱引伸模具......................................49 4-3-2.室溫引伸沖壓模具................................49 4-4.全尺寸工件之成形模具幾何形狀與成形邊界探討.........52 4-4-1.主要特徵成形斷面介紹............................52 4-4-2.次要特徵成形斷面介紹............................53 4-5.全尺寸工件之壓力-時間成形曲線設計..................55 4-5-1.折彎預成形+超塑成形之成形曲線...................55 4-5-2.折彎預成形+引伸製程+超塑成形之成形曲線..........58 4-6.全尺寸工件之超塑成型參數...........................60 4-6-1.預折彎圓角......................................60 4-6-2.引伸量與壓料力..................................60 4-6-3.成形應變速率....................................60 4-6-4.成形溫度........................................60 第五章:試驗結果與討論....................................93 5-1. 長方形開口盒平板之超塑成型.........................93 5-1-1. 長方形開口盒試驗結果(一)........................93 5-1-2. 長方形開口盒試驗結果(二)........................95 5-1-3. 長方形開口盒試驗結果(三)........................98 5-1-4. 長方形開口盒試驗結果(四).......................100 5-1-5. 長方形開口盒試驗結果(五).......................103 5-1-6.長方形開口盒試吹總結............................106 5-2.全尺寸工件之超塑成型(折彎預成形+超塑成形)結果......108 5-2-1.整流罩之“V型折彎+超塑成形”製程試驗結果(一)....108 5-2-2. 整流罩之“V型折彎+超塑成形”製程試驗結果(二)..112 5-3.全尺寸工件之超塑成型(折彎預成形+熱引伸成形+超塑成形)結果......................................................114 5-3-1.整流罩之“V型折彎+熱引伸成形+超塑成形”製程試驗結果(一)....................................................114 5-3-2.整流罩之“V型折彎+熱引伸成形+超塑成形”製程試驗結果(二)..................................................116 5-3-3. 整流罩之“V型折彎+熱引伸成形+超塑成形”製程試驗結果(三)..................................................118 5-4.全型工件之超塑成型(折彎預成形+室溫引伸成形)結果....122 5-4-1. 整流罩之“V型折彎+室溫引伸成形”製程試驗結果(一)....................................................122 5-4-2. 整流罩之“V型折彎+室溫引伸成形”製程試驗結果(二)....................................................125 5-5.全尺寸工件吹製結果討論.............................128 第六章:結論.............................................151 參考文獻................................................154 附錄....................................................158

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