動態模溫控制模擬驗證之研究

Study on Simulation and Verification of Dynamic Mold Temperature Control

江志良(Chih-Liang Chiang)

指導教授 ： 陳夏宗

中原大學/工學院/機械工程研究所/碩士(2004年)

https://doi.org/10.6840/cycu200400538

摘要

隨著科技的進步與創新，諸多產品逐漸要求短、小、輕、薄，為了使塑料在充填階段有更好的流動性，必須升高模具溫度達到精密成型的要求，所以無法避免較長的成型週期。動態模溫製程可以控制成型過程中，在充填保壓階段維持高模溫，待冷卻階段導入冷卻水快速降低模具溫度，則可減少成型週期且改善成品品質。本論文主要是針對動態模溫控制與模擬分析作一研究，對動態模溫製程進行實驗並與模擬分析結果比較，並實際進行感應加熱對改善薄殼件縫合線之案例實驗，以達到改善成品品質與降低射出成型成型週期之目的。
本文中以模溫機、加熱管與感應加熱對模板進行加熱與冷卻實驗，並以ANSYS對上述三種加熱方式作加熱與冷卻的溫度場分析，比較實驗與模擬結果，討論不同模具加熱方式之加熱及冷卻效率與模具表面溫度分布均勻性。研究中使用動態模溫控制技術進行案例實驗，除驗證此製程之可行性，並討論此製程對減少成型時間與提高成品品質之效益。
對含冷卻水路與加熱管之模板進行動態模溫實驗與模擬結果顯示，ANSYS應用於動態模溫製程之溫度場模擬與實驗結果之趨勢相當接近。實驗中使用感應加熱僅需5秒便可將模板由50℃加熱至120℃，而加熱管與模溫控制機則分別需要64秒與272秒；使用感應加熱後所需的冷卻時間也比傳統加熱方式減少50﹪左右；此結果說明感應加熱之加熱與冷卻效率皆高於傳統的加熱方式。案例實驗結果顯示，動態模溫製程可有效縮短成型時間，且成功運用感應加熱於動態模溫控制製程，並可有效改善薄殼件之縫合線外觀與機械強度。

關鍵字

動態模溫 ； 感應加熱 ； 成型週期

並列摘要

The paper presents the study of establishment and analysis of dynamic mold temperature control system in injection molding process. High mold temperature provided great contributions to conventional and advanced injection molded parts, mold design, trouble solving and decreased machine performance request in thin-wall and micro/micro-feature molding processes. Relative, high mold temperature also increases cooling time of injection molding cycle.
Dynamic mold temperature control can provide an ideal mold temperature condition, is to have a hot mold during the filling stage, and a cold mold during the cooling stage thereby improving quality of molded parts without increasing cycle time.
In this study, we build a dynamic mold temperature control system using different heating methods include traditional mold temperature controller and electric pipe and induction heating. We also processed mold temperature field analyses with heating apparatus by ANSYS software. The system was used on a flat steel mold plate with cooling channel design to execute heating and cooling efficiency experiments. Mold plate surface temperature was recorded by infrared thermal image system and thermometer. The experiment results were compared with the simulation results.
The heating response of the system, Mold surface temperature increases from 50℃to 120℃. It takes 5 seconds for induction heating, 64 seconds for electric pipe, and 272 seconds for traditional mold temperature controller. The results show that dynamic mold temperature control system with induction heating makes an ideal rapid mold temperature control method for the injection molding process. It offers good potential for shortening cycle times.

並列關鍵字

Dynamic Mold Temperature Control ； Cycle Time ； Induction Heating

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