目前在工業上超塑成形以氣壓成形法最普遍，近年由美國通用汽車公司(General Motors, GM)以超塑成形為基底而開發一種名為快塑成形的鈑片加工技術。本論文將快塑成形(Quick Plastic Forming, QPF)技術應用於製造金屬外殼，主要分為成形性與精準度的研究與探討。成形性研究採用了一般商用與超塑性的鋁合金鈑片進行實驗，藉由成形性測試、分析厚度與微觀結構觀察，來探討此製程是否具有製作金屬外殼的優勢，並評估適宜的材料。研究結果顯示在單次的氣壓成形製程中當成形時間在40秒以上時，模具的設計為影響鈑片能否完全成型的主要原因。綜合研究結果可推斷，透過減少模具中模厚度後，便可使用非超塑性5083板材來成形;並且進一步採用更薄之商用材料來達到降低成本的效果。 在精準度研究中，首先改進量具在夾持工件的設計並確認工件量測數值，進而討論量具形式的量測可靠度與重現性，並再確保量測數值的可靠與穩定與否，再對已成形鈑片之尺寸公差與取出方式進行探討。因在成形性研究中所使用之捲曲造型金屬外殼模具，其具有製程時間過長與成品品質不穩定等因素。故於重新設計模具並增加脫模拉桿機構，希望有效改善製程效率與尺寸精度。讓氣壓成形製程更具有經濟效應與市場競爭力在金屬機殼的製造。研究結果顯示，使用機構取出方式能大幅降低製程時間與提升生產效率，間接降低模具溫度的散失。尺寸公差方面，統整三套模具所得到的尺寸量測數值，使用標準差計算出公差等級，得到氣壓成形製程為IT10到IT14，其IT公差範圍與CNC 切削和沖壓加工相近，說明此製程在金屬機殼製作上具備一定的商業價值。 ;This thesis focuses on applies the Quick Plastic Forming (QPF) technology to the manufacture of metal shells, which is mainly divided into the research and discussion of formability and accuracy. The formability research uses commercial and superplastic aluminum alloy sheet for experiments. Formability testing observed thickness and microstructure, to explore whether this process has the advantages of making a metal shell, and to evaluate the material of the sheet. The research results show that the design of the mold is the reason that affects whether the sheet can be completely formed. Comprehensive research results can be inferred that when the thickness of the middle mold is reduced through the improved design of the mold, general commercial sheet materials can be used for forming. In the study of dimensional accuracy of QPF, first improve the design of the measuring tool and the dimensional tolerance and the extraction method of the work piece are discussed. Due to the shallow rounded die affect, the process time is weak and the quality of the finished product is unstable. Therefore, the die was redesigned and the demolding mechanism was added. The research results show that the proposed mechanism can significantly decrease the process time, because it replaces most of the operations of specimen movement after forming completely. In terms of dimensional tolerances, the standard deviation is used to calculate the tolerance level, and the tolerance level of the quick plastic forming process is IT10 to IT14. The IT tolerance range covers the scope of CNC cutting and stamping processing, indicating that this process has certain commercial value in the production of metal casings.
