模內裝飾射出成型冷卻管路與模具結構之最佳化設計

本研究第一部份將使用有限元素分析軟體ANSYS，模擬在模內裝飾 (In-Mold Decoration, IMD)射出成型製程中各個接觸面的溫度趨勢，並且和文獻上的數據比對，確認分析之正確性。接著參考相關冷卻管路設計規範，以固定公模側冷卻管路，改變母模側的冷卻管路設計為方向，提出非對稱式冷卻管路設計，以縮小在IMD射出成型成品兩側的溫差為目標。結合田口方法的實驗設計，以母模側冷卻管徑大小、冷卻管路至模具表面距離、冷卻管路間距與冷卻管壁熱對流係數為控制因子，提出最佳化之設計參數。從田口方法分析當中得知，當母模側冷卻管路至模穴表面距離越近時，IMD成品兩側的溫差越小。並且透過變異數分析(Analysis of Variance, ANOVA)得知，影響冷卻效率的控制因子當中，以冷卻管路至模穴表面距離最為顯著。第二部份探討冷卻管路設計對於模具結構的影響，在結合射出壓力與模具受熱所產生之熱應力影響的情形下，以冷卻管路一半的間距、冷卻管路至模穴表面距離與冷卻管路直徑作為控制因子，結合田口方法的實驗設計，以最小化之模具最大應力值為目標，提出最佳化之參數設計。從田口方法分析當中得知，當冷卻管路直徑越小時，模具承受的應力越小。並且透過ANOVA分析得知，冷卻管徑大小對於模具結構的影響最為顯著。

關鍵字

In-Mold Decoration ；田口方法；非對稱式熱傳導；冷卻管路設計； ANSYS ；模具結構；最佳化

並列摘要

The first part of this study discusses how to use the unsymmetrical cooling channel design under the rule to reduce the unsymmetrical heat transfer on the In-Mold Decoration (IMD) part. Also using the Taguchi Orthogonal Array to do experimental design, take the pitch between the channels, the distance from mold surface to center of the channel, the diameter of the channel and the convection on the channel wall as the control factors to propose optimal design of the cooling channel. According to the Analysis of Variance (ANOVA), may know the largest control factor affect the cooling efficiency is the distance from mold surface to center of the channel. The second part of this study discusses the effect of the cooling channel design to the mold structure. Taking the half distance between the wall of two cooling channels, the distance from the wall of the cooling channel to the cavity surface and the diameter of the cooling channel as the control factors. According to the Analysis of Variance (ANOVA), may know the largest control factor affect the mold structure is the diameter of the cooling channel.

並列關鍵字

cooling channel design ； mold structure ； In-Mold Decoration ； unsymmetrical heat transfer ； optimal design ； ANSYS ； Taguchi Orthogonal Array

參考文獻

[1] Wong, A. C. & Liang, K. Z. (1997). Thermal Effect on the Behaviour of PET Films Used in the In-Mould Decoration Process Involved in Plastics Injection Moulding. Journal of Materials Processing Technology, 63(1-3), 510-513.

[2] Huang, R. D. (2003). Study of Injection Molding Characteristics for PC/TPU In-Molding Decoration. M.S. Thesis, Chung Yuan Christian University.

[5] Wang, H. S. (2007). Study of Variable Mold Temperature to Improve the Surface Quality of Microcellular Injection Molded Parts. M.S. Thesis, Chung Yuan Christian University.

[6] Tsai, Y. L. (2007). Application of Carbon Coating of the Mold Insert in Micro Injection Molding. M.S. Thesis, National Cheng Kung University.

[9] Chen, S. C., Li, H. M. Huang, S. C., & Wang Y. C. (2010). Effect of Decoration Film on Mold Surface Temperature During In-Mold Decoration Injection Molding Process. International Communication Heat and Mass Transfer, 37(5), 501-505.

國際替代計量

模內裝飾射出成型冷卻管路與模具結構之最佳化設計

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