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熱擠製鋁合金6061三階齒輪之研究：有限體積模擬與實驗的比較

為了解決鋁合金7075與6061比較的問題，作者PAVAN SAI PAGADALA 這樣論述：

The study introduces a novel technique, bidirectional hot extrusion and uses a selective laser melting (SLM) machine with Inconel 718 alloy to additive manufacturing of a helical-spur-helical three-stage gear. An experimental investigation is carried out on Aluminum 6061 alloy by performing the Ten

sile test on the cylindrical specimen machined based on ASTM E-8M standard to compare the estimated results with the available library data. To determine the effectiveness of the introduced techniques, firstly a computer-based design followed by analysis is carried out with the help of MSC Simufact

forming and MSC Simufact additive. The analysis includes the Finite Volume Method (FVM) for the triple gear and the Powder Bed Fusion (PBF) technique for gear die. Convergence test has been performed using the FVM with Aluminum 6061 as the material based on varying mesh element size. Simulation is e

xecuted at three different temperatures 350°C, 400°C, 450°C, and numerous attempts were made to determine the optimal time and velocity for obtaining a more favorable gear profile and the computation time. With a constant optimal time of 10s and varying the mesh element size between 0.5 to 1.6 mm wi

th the input velocity of 1.75, 2.0 & 2.25 mm/s, it is observed that the die filling rate is very accurate, and crack formation on the tooth bed is minimum. The input parameters of PBF in Simufact additive such as scan velocity, laser power, beam width, and layer thickness are optimized to evaluate t

he residual stresses and distortions formed in the fabrication of gear dies which yielded satisfactory results. IFUM (Institute for forming technology and forming machines) model is employed to evaluate the material flow rate and underfilling of the gear tooth. Considering the simulation results, ex

periments are performed to fabricate the gear die using the SLM technique and the triple-gear using monodirectional hot extrusion (due to unavailability of required bidirectional hot extrusion machine setup). Surface machining is performed to the gear die to obtain a favorable gear profile closely m

atching the simulation results.

鋁合金銑削加工應力釋放分析

為了解決鋁合金7075與6061比較的問題，作者鄭欽文 這樣論述：

鋁合金是一種應用極為廣泛的有色輕金屬，由於鋁合金的密度低、強度高、導電性高、耐腐蝕，舉凡建築、車輛、航空科技、國防武器及一般機械製造中，都有著相當程度的應用。在鋁合金的加工應用中，最難掌握的莫過於加工變形的問題，不論是銑削、車削，或是沖壓成形，鋁合金因加工而產生的熱變形一直都是加工作業中，對加工精度、平整性等，造成極為難以控制的因素。鋁合金加工變形的影響因素眾多，其與材質、零件形狀、加工條件等都有關係。主要為毛坯內應力、切削力、切削熱、夾持力等所造成的，而這些加工應力所形成的變形，不僅影響加工過程中的精度誤差，更重要的是在加工完後，仍有一段持續應力釋放的變形的時間，影響工件後續加工作業的精度

控制，造成作業排程的困擾與生產效率降低。因此，如何掌控鋁合金加工後應力釋放的變形，是一項值得重視的課題。本研究針對6061-T6鋁合金在銑削加工後所產生加工應力的釋放變形做一分析，以實驗方法，量測在不同的進給、切削深度、有無外力夾持等條件下，銑削加工後所產生的應力釋放時間的變形趨勢，並將其結果加以統計分析，從中了解加工參數與外力夾持的變形量影響程度，藉此取得能提高加工效率而又不失加工品質的加工參數，進而對於後續排程與製造程序提供優化的參考。