| Summary: | 碩士 === 國立虎尾科技大學 === 機械與電腦輔助工程系碩士班在職專班 === 106 === In recent years, the application of CAE is quite common. In the field of screws, the demand for production-oriented, high-precision components has increased. It is expected that CAE can find the best production mode under the choice of different machines.
This study compared processes among a variety of forging machines, focusing on flange hexalobular, AISI1015, wherein SolidWorks was used first to conduct construction of physical body. Then, finite element analysis software, Deform2D/3D, was used to conduct two-part analysis, which are flange hexalobular screw’s process simulation of 3D3B on multi-stage cold forging machine and heading machine-applied process simulation of 1D2B; the feasibility of reducing the process from 3D3B to 1D2B was assessed by observing the change of flow speed, stress distribution and the force that molds were imposed during forming period.
Indicated from the findings of pre-forming blank of 3D3B and 1D2B by applying Deform2D/3D, in terms of the flow deformation, it suggested that the material of 3D3B squeezed backward at the preliminary forming stage; however, none of similar situation occurred to the blank flow of 1D2B, which is an indication that 1D2B had more stable blank flow than 3D3B; in the aspect of equivalent-effected stress, due to the fact that diameter reduction of 3D3B at Phase 1 and cold forging on the head at Phase 2 were fulfilled at Phase 1 of 1D2B, hence, 1D2B blank bore bigger stress during deformation process, while 1D2B blank bore more stress than 3D3B by 6.35%; in the aspect of the force that the mold was imposed, the simulation result shows that the total load of Six Lobe Punch and ejector pin of 1D2B bored lower than that during the process, 3D3B, by 27.7%. The consolidated analysis on three items as above shows that the process reduction from 3D3B to 1D2B had bigger impact on the plastic deformation for blanks; however, the total load showed lower upon reduction on Six Lobe Punch and ejector pin. After forging the finished product through actual molding process and comparing , analyzing it with simulation, the shape of finished product throughout each phase of using multi-stage cold forging machine and forging by heading machine correspond to the result in the simulation, indicating that finite element analysis software-applied analysis on the process had a certain level of reference value. Doing so can reduce the pilot-run and molding costs with errors, also increasing production efficiency.
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