外部式感應加熱應用於模具3D結構設計之研究

Investigation on Heating Injection Mold of 3D Structure Design by Using External Induction Heating

謝宗顯(Tsung-Hsien Hsieh)

指導教授 ： 陳夏宗

中原大學/工學院/機械工程研究所/碩士(2015年)

https://doi.org/10.6840/cycu201500555

摘要

隨著消費市場增長，消費性電子產品在數量與外觀品質上的要求也開始逐漸被重視，而以塑膠材料為大宗的產品主要以射出成形作生產，『動態模具溫度控制』技術可以提供較快速的模具升溫效果之外，塑膠產品外觀上的縫合線、浮纖等問題都可透過高模溫的方式解決。動態模溫技術除了縮短成型時間之外，產品也可達到更高的經濟效益。
本研究利用立體式感應線圈對模具表面進行外部式加熱實驗，並探討該應用的可行性與加熱後模面溫度均勻性。利用CAE軟體對平面式線圈與立體式線圈做模擬分析，對該設計在感應加熱上的可行性做初期評估後，以不同基礎模溫、加熱間距以及加熱秒數等參數對模仁模面加熱並探討其加熱後的溫度均勻性，並針對加熱後溫面溫度差異過大等問題進行討論與改善，再利用ANSYS軟體做溫度場的分析模擬進行驗證。
研究結果顯示，利用ANSYS所做的初期評估顯示出立體式線圈對於在非平面模面的感應加熱優於以往平面式的感應線圈。在不同模具溫度、加熱間距與加熱秒數等實驗參數的外部加熱實驗中得知，當加熱秒數降至3s時模仁側邊的兩個梯形面的平均溫度差異百分比分別為41.3%與47.5%，為所有實驗組中溫差最小、加熱均勻性最好的；而在改善溫差的實驗中發現，以設計三的感應線圈所得到的加熱結果最好，模仁側邊的兩個梯形面的平均溫度差異百分比分別從41.3%與47.5%下降至21.3%與24.5%，縮小加熱面的平均溫差而使整體加熱均勻性提升，而感應線圈中心加裝導磁塊的設計可以改善線圈中心加熱不均的現象
在實驗與分析中，成功的將立體式感應線圈應用於模具模面外部加熱測試，並證明其可行性以及與實驗結果趨勢相符，成功建立立體式感應線圈於模具外部加熱的3D磁-熱耦合模擬分析。

關鍵字

動態模溫控制；感應加熱；3D磁-熱耦合模擬

並列摘要

By growing of the consumer market, the amount of production and the surface quality of 3C product are gradually emphasized. Because of plastic products, made by injection molding, the utilizing of dynamic mold temperature control raised up mold temperature and cool down in a short time brings about the defect of the product appearance solved; additionally, decreasing of shorter cycle time to provide higher economic benefits.
In this study, we used 3D induction coil design for exterior heating, and investigated the heating feasibility and temperature uniformity. For investigation, at first, we used ANSYS to evaluate the heating feasibility between 2D traditional coil and 3D induction coil design. Secondly, heating experiment was conducted by changing mold temperature, heating distance, and heating time. Finally, we tried to improve the temperature uniformity by four different kind of coil designs and verified with ANSYS results.
The results shows that the 3D design can heat up non-planarity of mold surface efficiently instead of the 2D design’s. Moreover, the experiment results reveal that the ideal temperature uniformity was appeared under 3s heating time, and the temperature difference of two trapezoidal sidewall mold surfaces are 41.3% and 47.5%. In the last part, we succeeded to improve temperature discrepancy on two sidewall surfaces. The temperature discrepancy are from 41.3% and 47.5% to the better result of 21.3% and 24.5%, respectively. In other words, the temperature uniformity was enhanced as well, especially, in the Design 3. Furthermore, the design in which put magnetic block in the center of induction coil can improve the heating uniformity.
In the experiment and analysis, IHTC test of 3D induction coil was built successfully, and verifying with the simulation results.

並列關鍵字

dynamic mold temperature control method；Induction heating temperature control；3-D thermal and electromagnetic analysis

參考文獻

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