|
大綱
|
摘要
漸進成形加工乃利用成形工具沿著設定的路徑移動，逐步造成板材變形以製作出所需要的工件，無需製作和更換昂貴的模具，因此能有效地進行少量製造，從而實現產品的客製化。儘管漸進成形技術具有高度的自由度，其精度控制與預測仍未得到充分解決。本研究運用有限元素軟體Abaqus對AA1050-O板材單點、雙點漸進成形進行回彈分析，目的是研究兩種加工方法的異同。本研究主要分析單點、雙點漸進成形的回彈現象，量化回彈並討論漸進成形中回彈的成因。
從模擬的結果得知，雙點漸進成形和單點漸進成形相比，雙點漸進成形整體的回彈量較大，不過可以透過路徑補償提高加工精度，也因此使用雙點漸進成形可以更有效地控制變形，從而達更好的輪廓和精度。由於單點漸進成形與雙點漸進成形的加工路徑不同，造成單點漸進成形的局部回彈是向杯內回彈、雙點漸進成形則會是向杯外回彈。同時，因為包辛格效應會導致材料軟化，在同樣的加工條件與加工路徑下，其模擬結果的應變會比沒有考慮包辛格效應的模型來得大。而單點漸進成形和雙點漸進成形不管有沒有考慮包辛格效應的模型產生的輪廓與實驗的輪廓都差異不大，代表方杯的形狀在漸進成形中可忽略包辛格效應的影響。在同樣的加工路徑下，因AA6061-T6的降伏強度較高，模擬結果的殘留應力會比AA1050-O來得大，且AA6061-T6在側壁回彈量的部分會比AA1050-O多。未來可建立不同材質板材的模型(如高強度鋼)進行CAE分析，或使用全模具來代替部分模具，以提升漸進成形在加工產業的應用。
關鍵宇：單點漸進成形 ； 雙點漸進成形 ； 回彈量化 ； AA1050-O ； CAE
Abstract
Incremental forming utilizes forming tools that move along a
predetermined path, gradually deforming the sheet metal to create the
desired workpiece. This process eliminates the need to create and
replace expensive molds, making it efficient for small-scale
manufacturing and enabling product customization. Despite the high
degree of freedom offered by incremental forming technology, accuracy
control and prediction remain unresolved issues. This study uses the
finite element software Abaqus to analyze the springback in
single-point and two-point incremental forming of AA1050-O sheets,
aiming to investigate the differences between the two methods. The
research mainly analyzes the springback phenomenon in single-point and
double-point incremental forming, quantifies the springback, and
discusses its causes in incremental forming. Simulation results
indicate that two-point incremental forming exhibits greater overall
springback compared to single-point incremental forming. However,
precision can be improved through path compensation, making two-point
incremental forming more effective in controlling deformation, thus
achieving better contours and accuracy. Due to the different
processing paths of single-point and two-point incremental forming,
single-point incremental forming results in inward springback towards
the cup, while two-point incremental forming results in outward
springback away from the cup. Additionally, since the Bauschinger
effect causes material softening, the strain in the simulation results
under the same processing conditions and path is greater in models
considering the Bauschinger effect compared to those that do not. The
contours produced by single-point and two-point incremental forming
models that do not consider the Bauschinger effect are closer to the
experimental contours, indicating that the shape of the square cup in
incremental forming can disregard the influence of the Bauschinger
effect. Under the same processing path, the residual stress in the
simulation results for AA6061-T6, which has higher yield strength, is
greater than that for AA1050-O. In the future, models for sheets of
different materials (such as high-strength steel) can be established
for CAE analysis, or full molds can be used instead of partial molds
to enhance the application of incremental forming in the manufacturing
industry.
Key words:
Single Point Incremental Forming(SPIF) ；Two
Point Incremental Forming(TPIF) ；Springback ；AA1050-O ；Computer
Aided Engineering (CAE)
|
