金屬射出成型料件燒結後整形製程改善

金屬粉末射出成型的料件，因燒結後造成尺寸變形量過大或過小，造成每次料件狀況不同，由於尺寸需要在規定公差內，對其進行二次加工的過程稱為整形加工，目的皆是為了讓良率品質提升並進行大量生產。本文以轉軸料件為例，探討金屬射出成型料件在生產時的變形量異常問題，並從中尋找問題與解決方案，由於生產時現有工站整形加工後良率不佳，造成料件重工、生產效率下降、外觀壓傷等問題，以及不必要的工時增加與人力浪費。為了使料件良率提升以利後續生產，並列出生產時所發現之問題。問題一尺寸變形量過大，造成生產時良率不佳。問題二生產遇到良率不佳時，無法快速分辨是機台調整問題，或此料件變形量是否過大，造成現場生產的困難與增加調機時間。依上述問題分析可能的原因，並對問題提出應對方案，針對問題一來料尺寸異常問題進行分析，為因應生產需求而增加新製程，並設計新模具依現有料進行測試，針對問題二，提供現場人員與技師，快速分辨料況的檢具，並從以上的分析與測試，找到最佳解決方案。

關鍵字

金屬粉末射出成型；整形加工；料件變形異常；製程分析

並列摘要

The size of the metal injection molded parts may become either too large or too small after sintering, causing each metal part may have a different size. So the part needs secondary processing when the size is beyond the specified tolerance. This process is called reshaping, the purpose of which is to enhance yield rate, improve quality, and carry out mass production. Taking shaft series metal parts as an example, the deformation problem of parts in metal injection molding is studied in this thesis, and problems are found and solutions are given. Because production technicians are suffering from low yield rates during metal parts production, it results in reprocessing, reduced production efficiency, cosmetic defects, and other problems. The following problems are found during production. The first problem is large deformation of metal parts, resulting in reduced production efficiency. The second problem is the difficulty to tell if the cause of low yield rate is due to ill machine setup or deformation of metal parts. This may delay the process of mass production. In this report, possible causes for the above problems are suggested and possible solutions are proposed. In response to the first problem, the range of deformation of metal parts is analyze, and new molds are created to test the metal parts to improve production yields. For the second problem, production line technicians and production engineers are provided with inspection tools to quickly distinguish the deformation of metal parts under different conditions, and based on the above mentioned analysis the best solution may be obtained.