田口品質工程應用於鋁輪圈高壓鑄造製程參數之研究

The Study and Application of Taguchi Method on the Die Casting of Aluminum felly

李思賢(Szu-Hsien Lee)

指導教授 ： 江行全

元智大學/工程學院/工業工程與管理學系/碩士(2000年)

摘要

【摘 要】
壓鑄(Die Casting)為一種以高壓形式將金屬液壓入形狀複雜之金屬材料模穴中的一種精密鑄造法，這種製程具有快速生產，成本低廉等優點。但是目前使用此種壓鑄方式生產之產品並不多，而且其整個製程系統非常複雜，以及所壓鑄出部品有許多的外觀瑕疵問題點。
近年來，田口方法(Taguchi Method)的應用推廣與發展已經蔚為一股風潮，因田口品質工程具有汎用性、再現性高的特性，企業界許多工程師、生產現場的技術人員均普遍的使用此方法，將品質設計於產品與生產製程之中，期能在競爭激烈的商場上持續發展，並佔有一席之地。
本實驗研究目的在於探討鋁輪圈高壓鑄造製程的最適條件之參數組合，以及利用最低實驗成本達到高品質產品的水準，本研究主要為提出三階段製程最佳化改善策略，來進行鋁輪圈高壓鑄造製程參數最佳化設定以降低產品不良率，第一階段為透過管制圖來得到參數水準，第二階段為以田口方法來得到一組合適的參數組合實驗計劃以 直交表來進行控制品質因素，利用SN比值(Signal to Noise Ratio)做為品質特性評估標準，並由回應分析圖的結果得到堅耐性(Robust)製程以達到改善產品變異之目的，最後第三階段則引進反應曲面來調整參數至最佳化組合。經本研究策略改善結果，將實際製程之平均缺點數由1.03%降低到0.33%，改善幅度為68%。
關鍵詞：鋁輪圈高壓鑄造；田口品質工程；管制圖；反應曲面

關鍵字

鋁輪圈高壓鑄造 ； 田口品質工程 ； 管制圖 ； 反應曲面

並列摘要

【Abstract】
Die Casting is a precise method of casting which puts the liquid into a deform metal mold mode with high pressure. This has the advantage of mass production with low cost. By now there are only a few products manufactured in this way of casting. Besides, the process was generally complicated, and some of these products were subject to surface defects.
Recently, the progress and development of Taguchi method has become a tendency due to its recyclable features. This method has been playing important role in industrial community for manufacturers to promote their products with high quality.
The purpose of this experimental research is to explore the most suitable parameter combination in Aluminum felly’s high-pressure process and to reach the high quality level with the lowest development cost. This research mainly provides a three-step processes of optimum improving strategy to optimize the setting of the parameter for Aluminum felly’s high-pressure process and to reduce the failure rate. The first step is to get the parameter level through the control flew. The second step uses the Taguchi method to get the experiment plan with a proper parameter setting using the L27 orthogonal table to control the quality elements SN ratio as the standard for evaluate the quality feature and also the results of the reaction analyzed picture will be used in robust manufacture process in order to improve the product variant the final step using reaction curve align parameter up to optimum set. Through this research of improvement the defect of real process is reduced from 1.03% to 0.33. The improvement range is 68%.
Key Words: Aluminum felly Die Casting, Taguchi Quality Engineer
Control Charts, Response Surface

並列關鍵字

Aluminum felly Die Casting ； Taguchi Quality Engineer ； Control Charts ； Response Surface

參考文獻

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