應用感應加熱技術於模壓成型製程模具溫度歷程控制之評估研究

Evaluation Study of Induction Heat Technology Used in Mold Temperature Variation Control during Mold Compression Process

林育增(Yu-Tseng Lin)

指導教授 ： 陳夏宗

中原大學/工學院/機械工程研究所/博士(2015年)

https://doi.org/10.6840/CYCU.2015.00089

摘要

近年來，複合材料廣泛的運用於3C產品與汽車產業中，主要原因在於複合材料具有高強度、質量輕、耐磨耗等特性。在複合材料的模壓成型加工中，模具持溫與成型週期冗長的問題，是目前模具快速加熱技術無法克服的問題。基於此背景，在不改變製程並增加成本的負擔條件下，業界不斷的發展新的快速加熱技術來因應市場對於高品質複合材料加工的需求。
本研究是利用改變不同的內外部感應加熱時間與時序控制方式進行實驗，並以分析軟體ANSYS®做3D基礎平面模板溫度場分析與熱傳分析驗證，以驗證分析之可行性。研究結果顯示，當內部感應加熱時間設定為20秒，外部感應加熱延遲17秒且加熱3秒並搭配時序控制的方式，其持溫溫度達135oC且持溫時間達到28秒，故可證明內外部感應加熱搭配時序控制方式，可有效提升持溫溫度與持溫時間。ANSYS®應用於3D基礎平面模板溫度場模擬分析與實驗結果之趨勢相當接近。利用感應加熱3D磁-熱耦合模擬分析內外部感應加熱搭配時序溫控的模具溫控技術，當內部感應加熱時間由20秒提升至28秒時，其持溫溫度提升24.4%且持溫秒數增加3秒；當基礎模溫由40oC提升至80oC時，其持溫溫度提升20.9%且持溫秒數增加5秒。溫度歷程的比較中，電熱棒與內外部感應加熱搭配時序溫控的方式比較，可得知整體週期從788秒降至103秒，因此，使用內外部感應加熱搭配時序溫控的方式有效的改善成型週期冗長的問題。
在實驗與分析中，成功的將內外部感應加熱搭配時序控制進行基礎模板測試，並證明其可行性，成功開發內外部感應加熱3D磁-熱耦合模擬分析技術。

關鍵字

感應加熱3D磁-熱耦合模擬 ； 感應加熱 ； 模壓成型

並列摘要

In recent years, polymer composites has been grasped great attention in 3C and Automotive industries due to its advantages of relatively easy molding, high strength to weight ratio and being shaped to products of complicated geometry. Although polymer composites has a lot of advantages, there are still several bottle necks such as long cycle time, unable to provide a stable temperature duration for curing during compression molding waiting to be solved and improved.
The composite induction heating technology which combines mold exterior and mold base induction heating was used to achieve dynamic mold temperature with constant temperature duration required for molding so that the current bottle necks can be solved, simulation software ANSYS® was also used for the verification with experiments.
The results shows that the mold exterior induction heating time 17sec combined with mold base induction heating 20 sec with 3sec intermittence heating can achieved mold temperature 135oC and with duration time 28 sec, which were proved to have batter heating rate and longer/stable duration time. Furthermore, when the heating time increased form 20sec to 28 sec, the temperature can be raised by 24.4% and the duration time increased 3 sec, when the initial mold temperature was raised from 40oC to 80oC, the temperature can be raised by 20.9% and the duration time increased 5 sec. The results were also verified by ANSYS®. On the other hand, in the cycle time comparison between composite induction heating technology and heater heating we can found that the cycle time was reduced from 788 sec to 103sec at the same target temperature.
In the experiment and analysis, the success of the internal and external induction heating with timing control on the template test, and already prove its feasibility, the success of the establishment of an internal and external 3D magnetic induction heating - thermal coupling simulation analysis techniques.

並列關鍵字

Compression Molding ； Induction Heating ； Thermal and Electromagnetic Analysis

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