- 學位論文
含纖維複合聚丙烯材料在共射成型程序中芯層滲透形態變化與其機械特性關聯之研究
Study on the morphology variation of the core material penetration and the correlation to the mechanical properties in co-injection fiber reinforced polypropylene system
摘要
共射成型製程已經廣泛地應用於我們日常生活與各類科技產品之製作，它的特點是可以利用皮層與芯層之組合，創造許多新穎或是環保之產品。比如：利用純料皮層/含纖芯層組成外觀良好內在強韌之產品；或是透過適當地皮/芯層控制產生獨特之皮層自然穿透，構成特殊美觀之產品，提昇美感價值。然而，想完成前述在產品機械特性及美感具有競爭力之共射成品，無法一蹴即成，須考慮到影響共射成型的許多影響因子，從實務面來說，要掌握對芯層材料滲透型態的控制是一大挑戰。為此，本研究利用CAE模擬分析(Moldex3D)以及實務實驗研究，深入探討共射成型之機理。具體而言，我們採用標準拉伸試片(ASTM D638 TYPE V)的幾何模型作為研究之系統平台，並且選定純PP材料(簡稱材料 PP)及含纖PP複合材料(簡稱材料 30SFPP)進行研究。結果顯示，以PP材料進行單一射出基本流場行為觀察，CAE模擬結果與實驗相當吻合。接著以PP/PP系統為例，改變不同皮/芯層比例發現皮/芯層比例為60/40時，皮層材料還未被吹穿，且皮/芯層界面滲透距離最遠，分佈最均勻，定義它為最佳皮/芯層比例，以及在不同流率變化中得到流率增加會使芯層距離變短且往厚度方向增加。進一步，我們將模擬之芯層滲透距離進行量化。再者，對於共射流場內部的型態準確性利用電腦斷層掃描及影像重建進行驗證，發現在30SFPP/PP系統相較於PP/PP系統，芯層滲透呈現寬扁且短的介面。而在PP/30SFPP系統中，芯層滲透有抖動的行為。更進一步探討芯層滲透型態對機械性質的影響，當使用PP/30SFPP組合，內部使用含纖維複合材料能有效提升產品的機械強度，並且隨著芯層滲透距離的增加機械性質也會隨之增加，此部分利用CAE模擬並與實驗進行觀察，發現內部芯層深透型態為影響其機械性質一大主因。再者，芯層滲透的機理包括：皮/芯層比例為50/50、 70/30、 30/70也被深入討論；特別是當皮/芯層比例為30/70產生非常有趣之 “core-skin-core”結構，此部分是之前文獻沒有提過的，該等結構形成物理機制也深入探索。
並列摘要
The co-injection molding process has been widely used in our daily life and various products. Its special characteristic is to combine the skin and the core layers to create many novel or environmentally friendly products. For example: the structure of the virgin skin layer and the fiber-contained core layer can form a product with good appearance and inner toughness; the properly controlled skin/core ratio with breakthrough structure can produce a unique and beautiful product to enhance the aesthetic value. However, to produce the co-injection products with competitive mechanical properties and aesthetics in the product is not so easy. Many factors will affect the product design and development in co-injection molding processes. One of the most crucial factors to influence the quality of co-injection molding product development is to the prediction and management of the penetration pattern of the core material. To catch the penetration behavior of the core material, both of numerical simulation using Moldex3D and experimental study methods have been adopted in this study. Specifically, the geometric model of the standard tensile test piece (ASTM D638 TYPE V) has been used as the system. The pure polypropylene material (abbreviated as material PP) and polypropylene with 30 wt% short fiber reinforced material (abbreviated as material 30SFPP) are selected. The results show that through the basic flow field behavior testing of a single injection, both simulation prediction and experimental observation is quite matched. Moreover, through the skin/core ratio effect testing, the break-through is happened at skin/core ratio is 50/50 for PP/PP system. Hence, the optimized skin/core ratio is 60/40 (where the core ratio is maximum with skin break-through). This skin/core ratio break-through happened all at the skin/core ratio of 50/50 for other systems including 30SFPP/30SFPP, PP/30SFPP, and 30SFPP/PP systems. Moreover, the relation between the mechanical property and the core material penetration distance of the co-injected products has been discovered. Basically, the tensile stress of the co-injected products is proportional to the core material ratio. Furthermore, the physical mechanisms of the core material penetration behavior for the skin/core of 50/50, 70/30, and 30/70 have also been investigated. Specifically, when the skin/core of 30/70 system will generate a very interesting “core-skin-core” structure. The internal mechanism to cause this special structure was also discovered.
參考文獻
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