鋁壓鑄模具壽命延長研究(整合模溫機與模流分析)

本研究主要為鋁壓鑄模具壽命延長研究和製程建立，並結合模溫機與模流分析，傳統上，壓鑄模具之溫度控制和澆道系統之設計主要是依靠“經驗＂來決定，但要生產高品質的壓鑄品，僅憑“經驗＂並無法滿足模具設計的。藉由模溫機及模流分析協助壓鑄製程的掌控以及模具設計的開發，實有其必要性。實驗分為硬體實驗及軟體實驗。硬體實驗設備部份，利用模溫機控制模具溫度，包括加熱模具及區域除熱，來達到降低因模具溫度之熱循環所產生的熱疲勞龜裂。軟體實驗設備部份，藉著模流分析找出鑄件缺陷發生的可能位置和種類，再依據發現之缺陷研擬改進，以達到製程的掌控。使用模溫機來保持模具生產過程中溫度的穩定，來達到降低因模具溫度之熱循環所產生的熱疲勞龜裂。使用FLOW-3D模流分析，預測可能發生的鑄造缺陷，然後再進行開模，就能改善並避免缺陷的發生，以達到製程的掌控。整合模溫機與模流分析，來達到最後整體模具壽命的延長及產品不良率下降。

關鍵字

模具；整合模溫機；模流分析

並列摘要

This is a study on the process and system to extend aluminum die casting die’s tool life. Conventionally, die casting die’s temperature control and gating plan are designed based on experience. However, in order to ensure the quality of die casting, experience alone may not be sufficient. The need for die temperature controller and mold flow analysis to assist die cast production is indeed necessary. Experiment includes both software and hardware experiment. Hardware experiment includes controlling the die temperature using die temperature controller. By pre-heating the die and dissipating heat on certain areas of the die, we are able to reduce thermal fatigue on the tool steel as temperatures fluctuates and heat cycles through the die. Software experiment includes mold flow analysis to detect different types of defect and the respective area that may occur in the casting. Based on the result from the analysis, improvements are made in order to better control the process. With the use of die temperature controller we are able to maintain the stability of the temperature during production in order to reduce thermal fatigue. And using “Flow 3D” mold flow simulation software, we can predict the possible defect that may occur during die cast production. These are taken into consideration before the tool is build. Combining the two, we are able to obtain better control of the process in order to extend tool life and reduce scrap rate.