第四章 結果與討論
4.2 陶瓷沖頭分析
4.2.1 初步模擬實驗結果
針對外形參數的設計模擬結果，表4.7為模擬實驗參數陶瓷沖頭的最低壽命，圖 4.14~圖4.22為本次模擬實驗之陶瓷沖頭壽命圖。
表 4.7 模擬實驗陶瓷沖頭壽命
模 擬 數 據 A B C DL ife (cycle)
1 1 1 1 1 386030
2 1 2 2 2 382060
3 1 3 3 3 426910
4 2 1 2 3 2422800 5 2 2 3 1 2166300 6 2 3 1 2 2234200 7 3 1 3 2 9006100 8 3 2 1 3 10347000 9 3 3 2 1 9398700 No. 實 驗 因 子 水 準
圖4.14 條件(1) 陶瓷沖頭應力、應變與壽命圖
圖4.15 條件(2) 陶瓷沖頭應力、應變與壽命圖
陶瓷沖頭條件 1
2590.5 Maximum
0.38837 3.8603e+005 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
2590.5 Maximum
0.38837 3.8603e+005 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
494.68 MPa 2.4734e-003 mm/mm
4.1275e-002 mm Maximum
36.817 MPa 1.8409e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
494.68 MPa 2.4734e-003 mm/mm
4.1275e-002 mm Maximum
36.817 MPa 1.8409e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
陶瓷沖頭條件 2
2617.4 Maximum
0.38778 3.8206e+005 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
2617.4 Maximum
0.38778 3.8206e+005 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
495.42 MPa 2.4771e-003 mm/mm
4.6862e-002 mm Maximum
37.985 MPa 1.8993e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
495.42 MPa 2.4771e-003 mm/mm
4.6862e-002 mm Maximum
37.985 MPa 1.8993e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
圖4.16 條件(3) 陶瓷沖頭應力、應變與壽命圖
圖4.17 條件(4) 陶瓷沖頭應力、應變與壽命圖 陶瓷沖頭條件 3
2342.4 Maximum
0.39404 4.2691e+005 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
2342.4 Maximum
0.39404 4.2691e+005 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
487.55 MPa 2.4377e-003 mm/mm
5.2039e-002 mm Maximum
37.015 MPa 1.8507e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
487.55 MPa 2.4377e-003 mm/mm
5.2039e-002 mm Maximum
37.015 MPa 1.8507e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
陶瓷沖頭條件 4
412.74 Maximum
0.49542 2.4228e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
412.74 Maximum
0.49542 2.4228e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
388.2 MPa 1.7646e-003 mm/mm
3.3765e-002 mm Maximum
37.023 MPa 1.6829e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
388.2 MPa 1.7646e-003 mm/mm
3.3765e-002 mm Maximum
37.023 MPa 1.6829e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
圖4.18 條件(5) 陶瓷沖頭應力、應變與壽命圖
圖4.19 條件(6) 陶瓷沖頭應力、應變與壽命圖 陶瓷沖頭條件 5
461.61 Maximum
0.48825 2.1663e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
461.61 Maximum
0.48825 2.1663e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
393.91 MPa 1.7905e-003 mm/mm
3.794e-002 mm Maximum
35.799 MPa 1.6272e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
393.91 MPa 1.7905e-003 mm/mm
3.794e-002 mm Maximum
35.799 MPa 1.6272e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
陶瓷沖頭條件 6
447.59 Maximum
0.4902 2.2342e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
447.59 Maximum
0.4902 2.2342e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
392.32 MPa 1.7833e-003 mm/mm
3.864e-002 mm Maximum
37.067 MPa 1.6848e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
392.32 MPa 1.7833e-003 mm/mm
3.864e-002 mm Maximum
37.067 MPa 1.6848e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
圖4.20 條件(7) 陶瓷沖頭應力、應變與壽命圖
圖4.21 條件(8) 陶瓷沖頭應力、應變與壽命圖
陶瓷沖頭條件 7
111.04 Maximum
0.58409 9.0061e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
111.04 Maximum
0.58409 9.0061e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
329.27 MPa 1.4967e-003 mm/mm
3.1286e-002 mm Maximum
37.662 MPa 1.7119e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
329.27 MPa 1.4967e-003 mm/mm
3.1286e-002 mm Maximum
37.662 MPa 1.7119e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
陶瓷沖頭條件 8
96.65 Maximum
0.59398 1.0347e+007 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
96.65 Maximum
0.59398 1.0347e+007 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
323.78 MPa 1.4717e-003 mm/mm
3.1822e-002 mm Maximum
37.02 MPa 1.6827e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
323.78 MPa 1.4717e-003 mm/mm
3.1822e-002 mm Maximum
37.02 MPa 1.6827e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
圖4.22 條件(9) 陶瓷沖頭應力、應變與壽命圖
陶瓷沖頭條件 9
106.4 Maximum
0.58712 9.3987e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
106.4 Maximum
0.58712 9.3987e+006 cycles
Minimum Results
1.e+009 cycles Design Life
Safety Factor Damage
Life Type
Definition
All Bodies Geometry
Scope
Solved State
Safety Factor Damage
Life Object Name
327.57 MPa 1.4889e-003 mm/mm
3.5376e-002 mm Maximum
37.688 MPa 1.7131e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
327.57 MPa 1.4889e-003 mm/mm
3.5376e-002 mm Maximum
37.688 MPa 1.7131e-004 mm/mm
0. mm Minimum
Equivalent Stress Equivalent Elastic Strain
Total Deformation Object Name
4.2.2 S/N 因子反應分析
本次陶瓷沖頭望目值為二百萬衝次，在對表4.8 陶瓷沖頭S/N比做平均值分析後，
可得到各個因子於三水準間之S/N比值，如表4.9 陶瓷沖頭因子回應表，並且繪製 出因子回應圖，如圖4.23~4.26 陶瓷沖頭回應圖。
表4.8 陶瓷沖頭各組模擬實驗之S/N
表4.9 電腦模擬之陶瓷沖頭壽命S/N回應表
水準1 -124.091 -124.530 -123.327 -121.986 水準2 -108.111 -122.343 -124.695 -122.827 水準3 -137.574 -122.903 -121.754 -124.963 Delta -29.464 -2.187 -2.941 -2.977
Rank 1 4 3 2
Level
Factors
A B C D
1 386030 -124.158
2 382060 -124.179
3 426910 -123.935
4 2422800 -112.523
5 2166300 -104.418
6 2234200 -107.392
7 9006100 -136.910
8 10347000 -138.431
9 9398700 -137.383
No. y 平均值 雜訊比S/N
圖4.23 陶瓷沖頭寬度S/N回應圖
圖4.24 陶瓷沖頭高度S/N回應圖
-140.000 -135.000 -130.000 -125.000 -120.000 -115.000 -110.000 -105.000 -100.000
A1
A2
A3
-140.000 -135.000 -130.000 -125.000 -120.000 -115.000 -110.000 -105.000 -100.000
B1 B2 B3
圖4.25 陶瓷圓角S/N回應圖
-140.000 -135.000 -130.000 -125.000 -120.000 -115.000 -110.000 -105.000 -100.000
圖4.26 陶瓷沖頭長度S/N回應圖
-140.000 -135.000 -130.000 -125.000 -120.000 -115.000 -110.000 -105.000 -100.000
C1 C2
C3
D1 D2
D3
4.2.3 最佳化設計
本實驗依田口實驗方法所得到之最佳化參數，僅是在本次實驗中所設定的三 水準之中找出彼此間相對性最佳之水準，如表4.10 得知沖頭寬度貢獻度最大，由 S/N 曲線可得知陶瓷沖頭其最佳化組合如表 4.11 與表 4.12，為沖頭寬度(A2) 0.50mm，沖頭高度(B2) 10mm，沖頭圓角(C3) 50mm，沖頭長度(D1) 10.45mm，其 預估壽命為 2,166,300 衝次與目標值二百萬衝次，壽命提升 8.3%。
表4.10 陶瓷沖頭各因子的貢獻度
表4.11 陶瓷沖頭模擬預測結果
預測最佳化參數 A 2 B 2 C 3 D 1
雜訊比 S/N -108.111 -122.343 -121.754 -121.986 預測值
預測 Life
-104.418
2166300
因 子 貢 獻 度
沖 頭 寬 度 97.3982
沖 頭 高 度 0.5780
沖 頭 圓 角 0.9696
沖 頭 長 度 1.0542
表 4.12 陶瓷沖頭最佳化組合
50 50mm mm 37.5
37.5mm mm 25
25mm mm
C(沖頭圓角)
L
Levelevel
l
lL
Levelevel2
2 LevelL
evel33
A(沖頭寬度)
0.4mm 0.5mm 0.6mm
B(沖頭高度)
12mm 10mm 8mm
D(沖頭長度)
10.45mm 10.45 mm 10.55mm 10.55 mm 10.65 10.65mm mm 50 50mm mm 37.5
37.5mm mm 25
25mm mm
C(沖頭圓角)
L
Levelevel
l
lL
Levelevel2
2 LevelL
evel33
A(沖頭寬度)
0.4mm 0.5mm 0.6mm
B(沖頭高度)
12mm 10mm 8mm
D(沖頭長度)
10.45mm 10.45 mm 10.55mm 10.55 mm 10.65 10.65mm mm
因子