擺輾鍛造(orbital forging)
Keywords : Orbital forging, Orbital forming, Rotary forging, ... .
____________________________________________________________
擺輾鍛造技術研發自 1960 年代後期開始,主要集中在英國、波蘭、西德、日本及中國大陸。主要的使用工廠則多在歐洲,經過多年的研發後,擺輾鍛造生產線才成功的導入汽車鍛件生產市場。
擺輾鍛造與傳統冷間鍛造及熱間鍛造比較起來,可說是一種新的加工製程,由於具備以冷鍛方式將形狀複雜零件鍛造成近淨形或淨形鍛件之能力,故擁有極大之市場潛力。
從另一方面而言,擺輾鍛造能以傳統鍛造製程的 1/5~1/15 的負荷鍛製出相同尺寸的產品,因此在鍛機的投資成本上就要經濟的多,此外由於成形方式的不同及成形負荷的降低,自然也沒有一般傳統鍛造製程惱人的噪音及振動問題,對工作環境的改善及工作效率的提昇亦有極大的幫助。
擺輾鍛造的優點在於:在省能源、省力化的前提下可鍛造出近淨形(near net shape)或淨形(net shape)的鍛造件,同時也應發展多種少量、交期短的生產技術。
____________________________________________________________
1. 擺輾鍛造之工作原理
其上模之中心線相對於下模中心線傾斜了一個小角度 ,因此在成形時作用力僅作用於工件表面之局部區域,同時藉由上模繞著鍛機軸線的擺動,連續漸進式的輾壓工件表面,使工件變形量逐漸增加直到最終形狀為止。須留意擺動沖頭之組裝精度,避免沖頭破壞 [Sheu,2008]。____________________________________________________________
2. 應用
擺輾成形應用產品有:
- 齒輪相關產品:同步器齒環 [余,2007]、鋁鎂合金斜齒輪 [Samołyk,2013]、斜齒輪 [Sheu,2010]、齒條 (gear rack) [Han,2016]。
- 凸緣管件 [PMMT,2010] [Aksenov,2015]。
- 鉚接: [Qu,2016]。
- 鈑金件:手機殼 [Han,2017]。
____________________________________________________________
Reference
- [] 余征諴 (2007) 齒輪之壓機與擺輾鍛造製程分析與模具設計, 國立高雄應用科技大學, 模具工程系碩士班, 碩士論文. https://goo.gl/wDR1nJ
- [] J.J. Sheu,C.H. Yu (2008) The die failure prediction and prevention of the orbital forging process, Journal of Materials Processing Technology, Vol.201, pp.9-13. http://www.sciencedirect.com/science/article/pii/S0924013607011958
- [] 許進忠,余征諴 (2010) 不銹鋼管凸緣擺輾成形製程技術, PMMT 精密機械與製造科技研討會, pp.C22-01 -C22-06.
- [] J. J. Sheu,M. S. He (2010) A New Punch Profile Design for Orbital Forging of a Bevel Gear Part, Advances in Materials and Processing Technologies, Pts 1 and 2, Vol.83-86, pp.113-124. https://www.scientific.net/AMR.83-86.113
- [] Grzegorz Samołyk (2013) Investigation of the cold orbital forging process of an AlMgSi alloy bevel gear, Journal of Materials Processing Technology, Vol.213, pp.1692-1702.http://www.sciencedirect.com/science/article/pii/S0924013613001192
- [] L. B. Aksenov,S. N. Kunkin (2015) Rotary Forging of Hollow Components with Flanges, Advances in Mechanical Engineering, pp.1-5. https://link.springer.com/chapter/10.1007%2F978-3-319-15684-2_1
- Jie Qu,Guojie Zhang (2016) Numerical and experimental investigations of the shaft-clinching assembly process of automobile wheel-hub-bearing units, Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, Vol.230, pp.1741-1757. http://journals.sagepub.com/doi/abs/10.1177/0954407015622846
- [] J. Qu,G. J. Zhang (2016) Numerical and experimental investigations of the shaft-clinching assembly process of automobile wheel-hub-bearing units, Proceedings of the Institution of Mechanical Engineers Part D-Journal of Automobile Engineering, Vol.230, pp.1741-1757. http://journals.sagepub.com/doi/abs/10.1177/0954407015622846
- [] X. H. Han, Y. X. Hu,L. Hua (2016) Cold orbital forging of gear rack, International Journal of Mechanical Sciences, Vol.117, pp.227-242. http://www.sciencedirect.com/science/article/pii/S0020740316302120
- [] Xinghui Han, Qiu Jin,Lin Hua (2017) Research on Cold Orbital Forming of Complex Sheet Metal of Aluminum Alloy, Journal of Manufacturing Science and Engineering, Vol.139, pp.061013-061013-9. https://manufacturingscience.asmedigitalcollection.asme.org/article.aspx?articleID=2580830