A Study on Design and Analysis for Multi-Action Forging Die Set of Aluminum T-Joint

[[abstract]]傳統鍛造製程上材料之使用率只為40~50%，高達50~60%之材料成為廢料，致使成本高居不下。而這些金屬廢料製造過程極為耗能而且產生大量CO2，有礙環保。綠色製造已成現階段鍛造業必須要關注之課題。因此，在鍛造產業上若能發展創新之省料化鍛造技術，減少製程中之廢料，則非但能降低生產成本，提升競爭力，對於環境之節能減碳有所助益。而要達到此一目標就是要研究開發多軸複動化鍛造模具，進行省料化閉塞鍛造，鍛製近淨形鍛件。本研究以三通鋁合金管件接頭為載具，進行水平複動化模組技術之研究，首先收集相關文獻，加以分析複動化鍛造模組與成形機構設計，結合連桿機構與油壓式閉模鍛造機構，開發水平複動化鍛造模組。接著使用DEFORM-3D模擬軟體分析成形中材料流動之情形，尋找出最佳之參數，設計出三軸水平複動化鍛造模組。最後進行鋁合金之熱間鍛造實驗，探討模組之可行性，建立最佳化模組設計之準則，並根據實際鍛打之結果與模擬結果相互驗證。結果顯示，經DEFORM-3D模擬分析顯示三軸向水平複動化鍛造成形為可行方式，本研究之水平複動化模組可成功地將目標載具鍛造成形，且鍛件之流線顯示均勻合理，尺寸正確符合公差。[[abstract]]The yielding of conventional forging process is around 40~50%. It means up to 50~60% materials become as the scraps which results in higher cost for forging process. However, the manufacturing of the scraps consume a lot of energy and will produce a lot of carbon dioxide simultaneously which is harmful to our environment. Greem manufacturing process becomes as the concerned topic in forging industry at present time. Therefore, it is a must to innovate the materials-saving forging technology to decrease the scraps not only for costdown but also for elevating competitiveness, and then helpful for the environment protection due to decreasing carbon dioxide. To attain this goal, the multi-rams and multi-action forging die needs to be developed to conduct the materials-saving closed die forging process. In this study, the T joint is used as the vehicle to investigate the die set of horizontal split and horizontal multi-action forging. First, the information of developed multi-action forging die set will be collected and be analyses.?Then, the die set is designed and developed by combining a link mechanism and a hydraulic clamping mechanism.?At the same time, the forging simulation software DEFORM is used to analyze the stress and strain in the die as well as the situation of material flow during forging.?The optimum conditions of the process will be investigated and established by the simulation results.?According to the optimum conditions, the horizontal multi-action forging die set with three rams will be tried