A Study on the Parameters for the Cold Forging Process with the Hollow Blank

[[abstract]]台灣製造產業在全球化的競爭下，已經愈來愈激烈，面對ECFA未來的挑戰，如何在生產前取得優勢和擁有解決產品瑕疵的方法，提升設計效率和縮短開發週期就成為目前最重要的課題。近年來，普遍依賴著有限元素法，應用在鍛造製程模擬分析中，以獲取模具與鍛件間之完整資訊。由於眾多的模擬參數，使得模擬次數過多，浪費了大部份的時間。 本研究將應用田口式品質工程法，在眾多製程參數中，由專業工程師討論出主要的製程參數，再選定直交表及水準值以最少的模擬次數，計算出最佳化之參數組合，並載入DEFORM- 3D模擬分析，來探討模擬結果之可行性，確實縮短模擬次數及時間。模擬分析上沖頭模具結果顯示，高主應力區位置與實驗模具斷裂位置相符合。修正上沖頭斷裂位置之Ｒ角與斜度，最大應力值由1720MPa下修至1480MPa，解決了上沖頭斷裂之狀況。其應用之手法，可提供日後鍛造產業，精密冷間鍛造開發設計之參考。[[abstract]]Due to the fact of the global competition and the ECFA impact Taiwan's manufacturing industry is very rival in the efficiency and cost benefit for the new product development It is the most important to improve the efficiency in the production management and shorten the cycle in the R&D stage for the purpose of the advantage in the pre-market competition In recent years the industry generally applied the simulation analysis of finite element method for the forging process to obtain the information between the mold and the forging As many of the parameters and simulation cycles the simulations prolong the R&D stage and the products lag behind in the market rival In this study we discussed the leading process parameters with the professional engineers by the application of Taguchi method and then selected the orthogonal array and the levels for the minimal simulation times and the best of the combination of parameters Applying the result into the DEFORM-3D simulation to explore the feasibility to cut down the times and duration for the simulation period Simulation results show that upper punch dies location of the main areas of high stress break location consistent with the experimental die Corrects upper punch break position Radius and the angle the maximum stress value was revised by the 1720MPa to 1480Mpa to solve the break of the upper punch position The experiment results are available for the precision cold forging R&D and production management in the forging industr