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

Development and Application of Molding-Guide Based Intelligent Reasonable Module for Injection Machine

尤婷儀(Ting-Yi You)

指導教授 ： 陳夏宗

中原大學/工學院/機械工程研究所/碩士(2011年)

https://doi.org/10.6840/cycu201100684

摘要

目前射出成型參數的調整大多依靠操作人員以試誤法或經驗來進行，無法獲得優化成型條件和穩定的產品品質。CAE模流分析雖可以預測成品在開模前可能發生的成型問題並提早應對，但無法將模流分析所得之成型參數在實際的生產中予以應用。本論文主要目的是建立一套以理論為基礎的智能化模組，讓使用者透過輸入產品資訊而得到可實際應用的成型參數。
本研究使用長平板狀模型(Strip model)進行CAE的模流分析與射出成型實驗，在成品模型的建立使用了四種不同厚度(0.5mm、1.0mm、1.5mm與2.0mm)來搭配不同流長比(L/T: 60、80、100與120)。實驗與模擬的材料採用ABS(PA-756)，模溫均固定為50 oC，塑料溫度則分別為220 oC、240 oC以及260 oC。藉由模擬與實驗在短射過程中進行充填時間的比對，可得到合理化的充填時間；接著再透過公式的計算，得到保壓時間、保壓壓力與冷卻時間，將此計算結果建立於成型導引智能化模組內以供現場實際試模時的參數使用。
本研究所建立之智能化導引模組經由現場實際導入的實驗結果可以得知，使用相關成型理論所計算出的成型參數在進行試模時，具有從傳統試模的25次縮減為13次以及試模時間從傳統的23分鐘縮減為13分鐘的優點，不僅大量節省塑料用量並縮短了試模時間，因此能夠提供業界作為在塑膠射出成型製造時一有幫助的參考工具以提升競爭力。

關鍵字

模流分析 ； 成型導引智能化模組 ； 射出成型

並列摘要

Injection molding is the most effective process to produce plastic products. The molding parameters are generally decided by trial and error method or operator’s experience, therefore, it spends more time to get correct parameters. CAE simulation can help the designer to predict the defects during process, then modify the mold design; however, the parameters within CAE simulation can not be applied to real production. The subject is to develop the molding-guide based intelligent reasonable module for injection machine.
The strip model that equipped different thickness(0.5mm、1.0mm、1.5mm and 2.0mm) and L/t(60, 80, 100 and 120) was utilized to do the CAE analysis and injection molding experiments. The plastic material was ABS (PA-756), and the mold temperature was 50 oC and melt temperature are separately 220 oC, 240 oC, 260 oC. The reasonable filling time can be done through experiment and simulation, and then packing time, packing pressure and cooling time were calculated by theoretical formulation. The calculation results were utilized to real production.
The experiment result shows, when use the parameters which calculated by the intelligent guide forming module can reduce the mold trial number from 25 to 13. And mold trial time reduces from the 23 minutes to 13 minutes. It’s not only saving the material but also reducing the packing time and cooling time. Creating the module which is established in this research can effectively reduce the mold trial time, save costs and provide a helpful reference tool to the plastic injection molding manufacture industry.

並列關鍵字

Rationalize forming module ； Injection molding ； CAE

參考文獻

18. 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. Tadmor, Z. and C.G. Goges, Principles of Polymer Processing, John Wiley and Sons, New York(1979).

3. Harry, D. and R. G. Parrott, “Numerical Simulation of Injection Mold Filling ”Polymer Engineering and Science, Vol. 10, No. 1,pp.209-214(1970).

4. Kamal, R. and S. Kenig, “The Injection Molding of Thermo-Plastics Part I: The Theoretical Model”Polymer Engineering and Science,Vol. 12,No.1,pp.294-301(1972).

5. 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).