與模具設計引導流程整合之模板設計最佳化分析

Optimal Design for Mold Plate in Mold-Design Navigating Process

林正豪(Cheng-Hao Lin)

指導教授 ： 鍾文仁

中原大學/工學院/機械工程研究所/碩士(2012年)

https://doi.org/10.6840/cycu201200708

摘要

塑膠射出成型的過程中，模穴內熔融塑膠的壓力非常高，塑膠射出成型機的鎖模系統除了需要開閉模具外，更需要抵抗模穴內熔融高分子塑膠的高壓。而塑膠模具在鎖模階段中，射出成型機的鎖模機構會施予極大的作用力於整套模具上，若公模板(Core Plate)厚度與支撐柱(Support Pillar)數量及位置的設計，未經由科學的理論依據，則如果模具鋼材使用過少，便會降低模具的壽命，也會影響成品的品質與尺寸精度；而模具鋼材使用過多，便會造成模具材料的浪費，也可能提升對機台的需求。
因此本論文主要研究在塑膠射出成型過程中，整套模具的結構特性，改變模座中公模板的厚度與支撐柱的數量及位置參數進行實驗，利用應變計(Strain Gauge)量測射出成型過程中公模板變形的應變值。並結合電腦輔助工程分析(Computer Aid Engineering, CAE)軟體，驗證實驗與模擬之趨勢的準確性，接著加入田口方法(Taguchi Method)進行分析模擬的實驗設計規劃，利用CAE在不同參數下分析公模板的變形量，並以不造成塑膠模具的破壞下，研究公模板厚度的最佳化與支撐柱的效益，使整體模具設計再次提升。確立了結合CAE流程的最佳化程序，將最佳化程序應用於標準模座的模板與支撐柱之設計，把最佳化的分析過程與結果轉化為知識庫，並導入至模具設計引導流程，以協助模具的開發，使模具能提高壽命與降低材料的浪費，而達到理論與實務的結合、經驗與知識的保存，以提升塑膠模具業的競爭力。

關鍵字

模具設計引導流程 ； 射出成型 ； 田口方法 ； 支撐柱 ； 公模板

並列摘要

Since in the process of injection molding the melted plastic will generate high pressure in cavity, the clamping system of the plastic injection molding machine requires to tolerating this high pressure. In the stage of clamping, the clamping machine will provide huge force to the mold. Therefore, the core plate thickness, the quantities and the locations of the support pillars are significant factors of mold design. For instance, fewer materials used in the mold would reduce the life of the mold also influence the accuracy of product size and quality. On the other hand, too much materials used in the mold would cause the waste of the materials and the increase the requirement of the machine.
The aim of this thesis is to investigate the structure of the mold in the process of plastic injection molding by altering the thickness of the core plates, the quantities and the locations of the support pillars. These experiments will use the Strain Gauge to measure the strain of the core plates in the process of injection molding. Moreover, the Computer Aid Engineer (CAE) will be applied to verify the trends from the experimental and the simulative values. On the basis of unknot damaging mold, the strain of the core plates from CAE will be subsequently analyzed to enhance the design of the plastic mold by Taguchi Method. Finally, the optimal analytical results will be transferred into the database and import in the mold-design navigating process. The advantages of the method reported in this thesis are extending the life of the plastic mold machine and diminishing the waste of the materials used in the process. In addition, the integration of theory and experiment and the preservation of experience and knowledge would also enhance the competition of the plastic mold industry.

並列關鍵字

Core Plate ； Taguchi Method ； Support Pillar ； Injection Molding ； Mold-Design Navigating Pocess

參考文獻

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