線上黏度監測應用射出成型製程

On-Line Viscosity Measurement and Monitoring Applied to Injection Molding Process

林志展(Chih-Chan LIN)

指導教授 ： 陳夏宗

中原大學/工學院/機械工程研究所/碩士(2013年)

https://doi.org/10.6840/CYCU.2013.00017

摘要

塑膠射出成型是實現工業產品零組件大量產出的重要手段。目前射出成型參數的調整大都靠操作人員以試誤或經驗來進行，無法快速獲得成型條件和產品品質。藉由CAE分析技術可預測成型問題並提早應對，在以往的經驗中，模流分析與實際參數有些差異，分析值無法直接設定於實際成型參數中，以減少工時並提升生產效益。本論文目的是建立一套以實際值為理論基礎的智慧型模組，讓使用者透過輸入簡單資訊，既可得到實際的成型參數。本研究使用長平板狀模型(Strip model)進行CAE模流分析。實際成型實驗，在模型建立使用了四種不同厚度(t)來搭配不同流長比(L/t)，在模穴裝置壓力傳感器(近澆口處)，與溫度傳感器(遠離澆口處)，量測充填壓力損失與充填時間，取得剪切應力、剪切率變化，套入公式求得黏度值，並將實驗量測值與分析值做比對驗證，探討實驗值與分析值的差異性。實驗與模擬的材料採用ABS(PA-756)，模溫設為50 oC，塑化溫度分別為220 oC、240 oC、260 oC。藉由分析與實驗於短射過程中進行充填的比對，得到合理化的充填時間，並利用不同機器去應證，建立於智慧型模組以供現場實際生產使用。
本研究經實際的結果驗證，建立ㄧ個標準模式後，所建立之充填模組用於智慧型控制器，往後的保壓模組、冷卻模組也可依此方式建立。

關鍵字

模腔壓力與溫度 ； 智慧成型導引 ； 黏度控制 ； 射出成型 ； CAE

並列摘要

Plastic Injection Molding realizes the important methods of an industrial product’s mass output of assembly parts. At present, defining calibration of injection molding parameters depend on operators going through several trial and errors or basing on self experience, thus it unable to quickly obtain ideal molding condition and product quality. Although CAE Analysis can estimate the possible occurrences of molding problems and to treat them ahead of time during pre-mold setup, but under known practices, there are some differences between Mold Flow Analysis and the actual parameters, an analysis value cannot be directly set in the actual molding parameters, in order to reduce man-hour or increase production efficiency. The goal of this thesis paper is to establish actual set values as theory based intelligent module, allowing users to simply input of information, as well as getting actual molding parameters. This research uses long-flat-plane-shape model (Strip model) and carries CAE Mold Flow Analysis. On the actual molding experiment, the established model uses four kinds of thickness (t) to match different flow length ratio (L/t), with cavity pressure sensor installation (near gate area), and cavity temperature sensor installation (far from gate area), thus, to measure pressure loss at filling stage and fill time difference, to acquire shear stress and changes on shear rate, to enter formula and gain knowledge of viscosity value, to compare and verify actual measured values and analysis values, and to apply discussions between analysis values difference. Experimental and simulation material uses ABS (PA-756), mold temperature is set at 50°C, melt plastic temperatures are 220°C, 240°C, 260°C, respectively. Due to analysis and test of short shot processes in relation to filling comparisons, in order to get hold of a realistic filling time, it is proven on different machines, establishing of intelligent module within so to provide actual production usage on the floor.

This research passes actual validated results, after establishing a standard mode, every established filling module uses of intelligent controllers, followed by switchover to holding pressure module, then cooling module may also comply accordingly.

並列關鍵字

Viscosity Control ； Injection molding、CAE、Cavity Pressure ； Cavity Temperature ； Intelligent Molding Walkthrough

參考文獻

7. 尤婷儀，”實用型成型導引智能化射出機合理化成型模組之應用與開發”，私立中原大學碩士論文(2011) 。

11. 鍾志鴻，”射出成型合理化參數評估系統-充填模組建立”，中原大學碩士論文 (2010) 。

1. Thienel, P. and G. Menges,” Mathematical and Experimental Determination of Temperature, Velocity and Pressure Fields in Flat Molds During the Filling Process in Injection Molding of Thermoplastics”Polymer Engineering and Science, Vol. 18,No.1,pp.314-320(1978).

2. Chiang, H. H.,”Numerical Simulation of Post-Filling Stage in Injection Molding with a Two-Phase Model”, Polymer Engineering and Scinece, Vol.34, No.4, pp.835-846(1994).

3. G.H., Choi and K.D. Lee and N. Chang and S.G. Kim, ”Optimization of Process Parameters of Injection Molding with Neural Network Application in a Process Simulation Environment”, CIRP Annals-Manufacturing Technology, 43, pp.449-452. (1994).