Who am I Teaching Course Metal Plastic Forming Lab.

20171128

Who am I

Teaching Course

Metal Plastic Forming Lab.

Forging

Sheet Forming

Wire Drawing

Extrusion

Industry Project

1

Who am I

2

實驗室名稱(Lab. Name):

金屬塑性成形及製程整合實驗室

Metal plastic forming and

process integration laboratory

實驗室主持人(Principal Investigator)

鄭芳松 Fang Sung Cheng

Email: [email protected]

關鍵字(keywords): Metal plastic forming, Forming and

process integration

Who am I

Teaching Course

Metal Plastic Forming Lab.

Forging

Sheet Forming

Wire Drawing

Extrusion

Industry Project

3

4

CADSolidWorks

CAEDEFORM

CAMUGMasterCAM

Die

Processing

Practice

Computer Aided Die Manufacturing Project

5

Computer Aided Forming Simulation Analysis

連續模設計與分析

成品圖

成形模擬圖

成形應力模擬圖成形應變模擬圖

6

連續模設計

Computer Aided Die Design

料帶佈置

1. 2. 3. 4. 5. 6. 7.

連續模立體圖連續模爆炸圖

7

Wire Electric Discharge Machine (WEDM)

8

Electric Discharge Machine (EDM)

9

縣政府獎杯製作

光學影像量測儀擷取之形狀

CNC MILLING

10

Die Processing Practice

將做好的各模具組件組裝起來，並鎖上沖床。

放入胚料，剪切成形，安裝吊環，成品完成。

Who am I

Teaching Course

Metal Plastic Forming Lab.

Forging

Sheet Forming

Wire Drawing

Extrusion

Industry Project

11

The study of direct heating billet within the forging dies

using resistance method

12

A Study of One-Step-Gradual Forging Process with the

Progressive Heating Method

13

Hole-Flanging Forming of High-Strength Steels Sheet by

Using One-Step Press-Forging Method

14

預拉力+加熱無眼模拉線+整圓實驗

15

縮減率2~3%之眼模做為預拉力負荷

二次眼模做修整

高週波加熱 冷卻+潤滑

後續待討論項目:平台速度、線圈直徑長度、抽製極限直徑

d

L

VØ D3Ø D1Ø D0 Ø D2

Ø D0 =6.5mm Ø D1 =6.4mm Ø D2 =4.9mm(目前) Ø D3 =4.10mm

Who am I

Teaching Course

Metal Plastic Forming Lab.

Forging

Sheet Forming

Wire Drawing

Extrusion

Industry Project

16

17

The Research of Forging for Supper Nickle Alloy

鍛造成品圖 製程模擬分析

鍛造不良圖

C276材料熱壓縮試驗

18

連續模設計

Continue Stamping Die Design

料帶佈置

1. 2. 3. 4. 5. 6. 7.

連續模立體圖連續模爆炸圖

19

The Research of Rounding for Bicycle Wheel Frame

20

https://www.youtube.com/watch?v=-

qdlDN3EqUY&index=8&list=PLchusgt_

mKW6qYYtrZ8ITPktQu6JdT8ey

https://www.youtube.com/watch?v=1P

yI3SQOfVc

自製捲圓模具參考

The Research of Extruding-Forging for Steerer

21

外徑D：44>D>30.6)

內徑d：28.6>d>24.6)

長度L：>288

厚度t：4.9>t>3

質量m=248.31g

體積V=91967.51mm3

不同素材尺寸之成形結果分析

22

Dout

(mm)

T

(mm)

L

(mm)

Damage Stress

(MPa)

Load

(kN)

37 5 170 0.245 189 529

44 9.6 95 0.102 172 436

0

100

200

300

400

500

600

0 50 100 150 200 250

沖頭負荷

(kN

)

沖頭行程 ( m m)

胚料尺寸 (外徑*厚度*長度 )

- - 4 4 m m * 9 . 6 m m * 9 5 m m

- - 37 m m * 5 m m * 17 0 m m

OP1模擬參數設定(材質：A6062)

23

The Drawing Parameters

Position(1/4Bearing±1/8，0、1、2)

Reduction：𝛼(15°、18 °、21 °)

𝛼

2= 7.5°、9°、10.5 °；

0.8d=0.8*30=24，

Approach：𝛽

2= 15 °

Bearing：L=0.1~0.3D，D=30

L=3~9，6、4、3、2)、

Friction=0.08(0.4)

Drawing

Speed=20(200)mm/min

The Research of Drawing for Lacrosse Frame

24

因子 反應與觀察對象

水準與參數設定

分析結果輸入

The Design Expert

for Optimization

25

Design Expert Study

26

243-11.7=231.3

(4.2%)

Drawing Speed=200mm/min241-11.7=229.3

Optimize parameter verification

27

The Research of Drawing Process for Ti-Wire

2min 3min 4min 5min >5min

Heating Unit

油壓式抽線機台(V=100MM/S=6M/MIN)

2噸油壓缸

DAQ擷取卡 荷重顯示器

5噸loadcell

眼模粉盒

電控箱

140kgf/cm2

5HP油壓馬達

油壓馬達調整為5HP，油壓缸直徑改為50mm，抽線速度提升至100mm/s。

28

The Research of Drawing Process for Ti-Wire

油壓式抽線機台強度分析(ANSYS)

規格 S45C WC

密度 7.87g/cm^3 15.7g/cm^3

降伏強度 343MPa 370MPa

極限抗拉強度

569MPa 530MPa

楊氏係數 206GPa 686GPa

浦松氏比 0.298ul 0.22

WC

其他皆為S45C

29

The Research of Drawing Process for Ti-Wire

DEFORM模擬分析模具溫度 胚料應力

胚料應變 應變率

30

The Research of Drawing Process for Ti-Wire

31

熱處理：650℃持溫4

分鐘可以拉線完成7

道次且皮膜全周存在

TGA實驗：只要空氣流量充足即可不須額外打氧氣

膜厚檢驗：

12/22-750FR2-原膜厚 1.525μm

12/22-750FR2-拉7道 1.02μm

2/14未拉線 1.52μm

2/17第一道 1.42μm

2/17第二道 1.05μm

2/17第三道 0.77μm

The Research of Drawing Process for Ti-Wire

The Research of Automatic Inspection

for Hole Inside Surface

32

1

.

2

.

3

.

4

.

5

.

1. 匯入圖檔2. 影像處理3. 影像比對4. NG條件設定5. 字幕顯示6. OPC Servers

7. GX Developer

瑕疵邊

6. 7.

PLCOPC

33

The Research of Automatic Control

for Baked Beans