S45C薄板之精密剪斷加工條件對斷面品質的影響之研究

Abstract

在精密剪斷加工的過程中，加工參數的設定是影響剪斷面之斷面品質關鍵。然而，影響剪斷加工製品斷面品質的參數有許多個，主要包括機具設備、材料性質與厚度、沖頭-沖模間隙、沖頭-沖模刀刃的鈍銳、壓板種類與荷重、逆壓料板壓力、潤滑劑之性質等多項。本研究以厚度2.0mm JIS S45C（AISI 1045）中碳鋼為材料，藉由改變沖頭-沖模間隙、沖頭-沖模刀刃的鈍銳、壓板壓力、逆壓料板壓力等四個參數，並利用田口式參數設計規劃實驗，探討材料於不同的參數組合下的剪斷面之斷面品質變化，嘗試找出具有最佳的加工參數組合。 據實驗結果顯示，越小之沖頭-沖模間隙及越大之壓板壓力，對於剪斷面上粗糙破斷面的比例與角度的提升有助益。另一方面，逆壓料板壓力僅對撓度有所影響。對於沖頭-沖模刀刃的鈍銳參數是否對剪斷面品質的影響程度，在本次實驗條件範圍內並不明顯。

During fine blanking process, many factors affect shearing surface quality of the products. Major factors include machines and tools equipment, material properties and thickness, punch and die clearance, cutting tools radii, blank-holder type and loading, counter punch pressure and lubricant properties. In this study a medium carbon steel sheet (JIS S45C/AISI 1045) was selected as the blanking material, series of blanking parameter combinations organized by Taguchi method and experiments conducted. According to the result of experiments, small punch and die clearance and large blank-holder load would be advantageous to reduce the percentage of fracture portion and the squareness of the shearing surface. However, the counter punch pressure seems only affect the surface deflection of the product. In this study, the variations of the cutting tools radii do not show any significant effect on the shearing surface quality.