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  • 學位論文

手機外殼之設計與模具開發研究

Research on design and dies development for cell phone cases

指導教授 : 楊東昇
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摘要


在現今3C產業的激烈競爭下,相關的行業無論是製造、加工、包裝、行銷,在今日的社會上都佔有非常重要的一環且競爭率頗大,因此要如何讓產品的品質上升、降低成本、使用壽命增加就變成了彼此競爭力差別的主要因素,以目前而言符合3C產品大多的需求:輕、薄,短、小而言,為鋁合金打開了它的運用新市場,鋁合金的優點為質量輕、散熱效果優良、成品均勻度高以及質量均衡、外觀變化多可成形多種形狀、安全性能優良,回收成本低的多項優點,幾乎符合3C產品的各項需求,總和以上之因素,在3C產品的應用特別是外殼方面,已經漸漸取代舊式的複合材料或者過重的鋼鐵材料,使鋁合金在這樣的優勢下被研發應用。 本文重點為針對產品的各項性能試驗作探討,並將模擬之多項數據做為產品設計以及模具設計、製造方面的重要數據;首先採用有限元素法進行成品的強度測試,透過有限元素法中的顯性求解法以及時間步數常控制進行成品的掉落碰撞測試,從多組(2.0mm、1.75mm、1.5mm、1.25mm、1.25mm、1.0mm、0.75mm)的實驗中得知成品進行掉落測後,不同厚度所產生之最大應變、最大應變、最大剪應力、壓應力分布位置均不相同,以及在同樣的設定的掉落測試中,0.75mm的掉落測試結果會產生破裂等相關數據,因此可透過此模擬取得改產品的可用情形等訊息;另外本文也透過拓璞最佳化理論對成品進行以不影響強度的前提下,進行成品的局部薄化,從模擬結果可得知對於外形最佳化而言,並非以厚度的多寡決定最佳化的結果,且經軟體呈現的可薄化區域,再進行成品模型的修改,並且再進行一次成品的衝擊試驗,以證實經過薄化之後的成品的可用情形。接著以有限元素法中的剛塑性變型之力學理論應用於模擬軟體進行外殼沖鍛成形的模擬,得到獲得該成品時所需要的沖鍛力參數,透過此項模擬得知對於鋁合金6061而言,溫度越高所需的成形力則是越低,且相對之成形性也越好等相關數據。 將以上所得之數據,套用於模具的設計與製造,可決定其外形、尺寸、選用材料等相關決定要素,如此之步驟可明確的節省試驗等開發成本,並能以此模具實際運用於成品上的製造,可以得到外型確定、強度夠、質量輕薄的成品,而且可因事先模擬數據的確認,達到避免無謂的測試及消費等目的,以致減少成本、提高生產效率的效果。

並列摘要


3C products in the current manufacturing industry is very competitive, the related industry is no matter a manufacturing and process, pack, sell, have a count for much position and have the big competition the rate in the society in present, the main factor of each other competition ability difference lies in how to let the quality rising of product and reduce cost and service life increment. For 3C products meet the required demand is light, thin, short, small, On its development of aluminum alloy, owning several advantages be like the quantities are light and spread hot effective, quantity balanced, appearance variety, the safe performance is excellent and recall cost is low for the aluminum metal alloy, various needs that almost match a 3C product. These factors, especially the case of product in the application of 3C product, the old type of compound material and over-weight steel material of have already gradually replaced, be developed and application because of the advantage of aluminum metal alloy. This focus is to test the performance of the product, And the number of simulated data as well as product design, mold design and manufacturing of important data; first , carries on the strength test of product by the method of finite element, with drop test by method of explicit and the time step control is through the element of the method of finite in order product , get the result by many experiments of set of drop test, the position of Max strain, Max stress, Max shear stress and distribution of pressure are not identical by different thickness, and the drop test is in the same enactment, produce a broken related data by the drop test of 0.75 mm thickness, therefore the condition improving a product obtains through that emulation. Another, the theories by the Topology optimization of the premise to doesn't influence strength to the product by this research, to carry on partial optimization of the product, be able to tell as a result for the emulation from the shape optimization, the result of optimization is doesn't decided by the amount of thickness, and the optimization district by the software, the modification in order to carried on product model, and carry on a drop test of the product again, confirm of can use of product by shape optimization. Then, carry on the simulation of forging of phone cases application of emulation software by mechanical theory of the deformation of rigid-plastic by method of finite element, get the parameter of the forming force use to product's manufacturing, got a information for the aluminum metal alloy 6061 through this emulation, need of take forming force more low because the temperature high, and oppositely of the data in formability getting better and better. Will above the data of Obtained, be applied to the design and manufacturing of dies, decide related main factor of shape, size and material, can be economical experiment cost and development cost by the step, be used for the of produce and applied to dies, can get the product of assurance features , strength enough and the quantity is lightweight, and can carry out to confirm of simulated data in confirm in advance, reach a purpose at the meaningless test and the consumption, reach the effect of reduce cost and raise a production efficiency.

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