氣體輔助射出成型的技術在國內已被廣範的應用,由於氣體具有可壓縮性,不容易作精密控制,加上對週邊操作環境敏感,因此在成品製程上因導入之氣體常有較不穩定的生產狀態,成型條件的控制上較為複雜。而射出成型機射出行程計量、材料溫度的穩定性,對於氣體輔肋射出成型品品質的重複性與安定性也有相當程度的影響。使用傳統上的經驗法則或試誤法來決定相關之製程參數,只會造成製造成本的提高及增加產品的不良率。藉由電腦輔助工程來模擬分析氣體輔助射出成型中的充填與進氣過程,並依據分析結果提供現場工程師做製程調整的參考方向。 本研究利用Moldflow模流分析軟體來獲得成品在成型週期中每一過程的狀況,藉由單一參數實驗方法,來進行個案中的各項製程參數做整體性的研究與探討,並以田口式實驗與變異數分析結果所獲得的最佳製程參數組合,來進行驗證實驗。第一個案例中,影響氣體穿透長度的主要因素順序為氣體壓力,熔膠溫度與短射尺寸。第二個案例中,影響氣體穿透長度的主要因素為氣體進氣延遲時間。儘管電腦模擬結果與實際射出成品的氣體穿透分佈範圍有明顯之差異,但是經由實際射出成型採用田口式實驗結果所獲得的最佳製程參數組合後,的確可獲得較佳的氣體穿透長度之表現,且成品的表面並無發現明顯凹痕。
The technique of Gas Assisted Injection Molding (GAIM) has been widly applied in Taiwan industry. Due to the compressibility of gas, the difficulties of precisely control and the sensitivity to the operation of surroundings, it is easy to make molding condition unstable in the molding process. Although injection machine takes precisely control in both injection stroke measurement and melt temperture, both factors quite affect the repeatability and stability of GAIM product quality. To choose from the related processing parameters by either traditional experiments or method of trial and error, only increases manufacture cost and failure rate. Using computer aided engineering (CAE) to simulate plastic filling, gas injection and holding pressure stage in GAIM, engineers can adjust processure based on analysis. This report is to use Moldflow software to collect information from a molding period of GAIM. It is to study and research each process parameter in an individual GAIM case using the single-parameter method. Furthermore, it utilizes Taguchi method and Variance analysis to find a key process parameter, then verifing the result with this parameter. In the first case, the main factor which influences gas penertation are gas pressure, plastic melting temperture and short shot percentage in sequence. In the second case, the main factor is the gas delay time. The difference is obvious for the distribution of gas penetration between the simulation analysis and the practical injection result. However through the practical injection improved experiment using the key process parameters from Taguchi method, the result does have a better distribution of gas penetration and the output has no sink mark on the product surface.
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