| Summary: | 碩士 === 國立成功大學 === 製造工程研究所 === 87 === In the past, the evaluation of the die for the forging process usually depends on engineer''s experience to solved problems with the "Trial-and-Error" approach. The systematic evaluation was not used in the die development stage, so the time, money and manpower were wasted.
In this study, a systematic approach was proposed to analyze the combinations of process and die design parameters for forging process. First, the Taguchi experimental design method was applied to obtain the parameters planning for computer simulation. Then, the finite element code DEFORM-3D was used to simulate the combinations of different forging process parameters to get the effects of process control and die design parameters on the die life. This can provide the key information for die design engineers to improve reliability of die design and die life.
The first case study is the motorcycle gear blank during orbital forging process. In addition to the evaluation by computer simulation, the forging load and displacement on the orbital forging press were measured in order to compare with the computer simulation results. The second case study evaluate the outer race of the constant velocity joints in an automobile during warm forging process. By adapting the Taguchi experimental design method, the number of simulation can be greatly reduced; therefore, the development cost can be reduced. Analysis of Variance (ANOVA) technique was used to analyze the effect of each factor and experimental error. Then, the forging load and die stress of the optimum combination of process and die design parameters was predicted.
By using the proposed systematic evaluation approach of die design in this study the die designer can observe the effects of die under different combination of parameters more extensively. The approach can also be applied to various forging processes.
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