鋁合金漸進成形之成形性與回彈分析

Abstract

漸進成形技術能輕鬆製造出傳統製程難以實現的複雜形狀和結構，有著靈活的生產能力，因此能有效地進行單件和小批量製造，從而實現產品的客製化。漸進成形還能節省時間和成本，無需製作和更換昂貴的模具，便可直接製作出實物。 儘管漸進成形技術具有高度的自由度，其精度控制仍然是一個重要且未得到充分解決的問題。本研究運用有限元素軟體ABAQUS對AA1050-O板材單點、雙點漸進成形進行分析，目的是了解不同邊界條件對精度的影響，並將這些結果作為後續優化漸進成形過程的依據。除了分析單點、雙點漸進成行的成形性之外，也分析其回彈現象。此外，本研究還討論了其他的加工誤差，如枕頭效應，這也是漸進成形中經常出現的一種不利現象，可能導致成形表面的不規則。由模擬結果得知包辛格效應對AA1050-O造成的影響，為材料降伏強度降低導致軟化，使得單點漸進成形初期加工時杯口處的彎曲(bending)尤為嚴重。而雙點漸進成形(TPIF)所造成的局部應力少於單點漸進成形，因此恢復的彈性能量也較小，因此減少了回彈量，提高了加工精度。同時，TPIF在厚度分布和精度方面比SPIF更好。因此可推知TPIF的加工機制下，可以更有效地控制變形，從而達到更好的厚度均勻性和更高的精度。

Incremental forming technology can easily produce complex shapes and structures that are difficult to achieve with traditional processes, it provides flexible production capabilities, effectively performing single-piece and small batch manufacturing, thereby achieving product customization. Incremental forming also saves time and cost, without the need to manufacture and replace expensive molds, objects can be made directly from electronic design files.Although incremental forming technology has a high degree of freedom, precision control remains a crucial yet unresolved issue. Springback phenomenon, as part of these errors, often leads to deviations in component dimensions, thereby affecting product quality. In addition, we also discuss other processing errors, such as the pillow effect, which is also a common disadvantage in incremental forming, which may lead to irregularities on the formed surface. The purpose of this study is to reveal the root causes of these errors and propose possible solutions to improve the accuracy and quality of incremental forming.This research uses the finite element software ABAQUS to analyze single-point and double-point incremental forming, with the aim of understanding the impact of different boundary conditions on accuracy. These results will serve as a basis for subsequent optimization of the incremental forming process. The data obtained from the analysis will help us better understand the springback mechanism and further propose effective compensation strategies to improve the efficiency and accuracy of the forming process.