羊毛氈針筆產品與模具開發之研究

塑膠產品設計之趨勢已朝向利用3D CAD軟體輔助設計、CAE軟體輔助產品設計之可行性驗證與利用實驗手法縮減產品製作成本並提高產出良率。本研究之羊毛氈針筆產品因本身具有針氈露出長度過長、產品外徑過大、內部空閒空間過多、產品重量過重等問題，故需要進行產品設計變更與改良。研究中主要利用Moldflow 模流分析軟體輔助塑膠產品之開發設計，模流分析在本論文的應用從產品樣式開發開始、並包括澆口設置、流道系統配置、充填最佳化、保壓最佳化、冷卻最佳化與翹曲變形分析等，以提供原始與變更設計比較之參考。從模流分析結果發現得知，最佳化澆口尺寸為2.0 mm；此外可藉由調整次流道進口端尺寸可達到流動平衡；同時冷卻水路對於產品翹曲變形之大小沒有太大影響。影響產品體積收縮之重要因素包括保壓壓力、熔膠溫度、射出時間等製程參數影響產品之體積收縮。最後由Moldflow模擬分析得到找出最佳化參數，並與實際射出結果比較，發現兩者體積收縮趨勢相同，驗證模流分析軟體輔助產品開發設計的應用，除可減少不必要試模成本外，亦可提供設計的經驗法則。而產品產出結果顯示，產品之線性收縮率皆在2 %以內。其中，以筆頭產品之最大外徑線性收縮率較大之原因，主要來自於利用強制頂出方式脫模所導致；原始設計之產品重量為35 g，經最佳化設計後之產品重量已縮減為13 g。

關鍵字

Moldflow ；體積收縮；最佳化設計

並列摘要

The Plastic product design trend has been toward the using 3D CAD software, CAE software, verify the feasibility of supporting product design and using experimental techniques to reduce production costs and increase product output yields. The felt-needle product has some issues as like felt-needle exposed too long, product diameter too large, the free space inside too much and the product weight overweight. Hence, product need to do design change and improvement. On this study, we using Moldflow software supporting the development of plastic product design. Moldflow analysis on this study application of product styles design, and including gate settings, runner system settings, filling optimization, packing optimization, cooling optimization, warpage optimization analysis and provide a reference for comparison. It was found from the Moldflow analysis that the best of the gate size of 2.0mm, then can find runner balance by tuning secondary runner size, at the same time that cooling channel has little impact with warpage. There are several important factors for Shrinkage effect, include packing pressure, melt temperature, injection time and other process factors. Finally, obtained best parameters by the Moldflow analysis, and then compare the results with actual injection and found the same trend between volume shrinkage. Moldflow verification assisted product development anddesign applications. In addition to test mode to reduce unnecessary costs and also provide the design rules of thumb.