以田口-灰關聯探討短玻璃纖維強化ASA共聚物射出成型條件最佳化與機械性質之研究

Optimizing Injection Molding Conditions and Mechanical Properties of Glass Fiber Reinforced ASA Copolymer by Grey-Taguchi Method

董承翰(Cheng-Han Dong)

指導教授 ： 邱薆蕙

國立虎尾科技大學/工程學院/機械與電腦輔助工程系碩士班/碩士(2016年)

摘要

現今丙烯酸酯、丙烯腈、苯乙烯接枝共聚物(Acrylonitrile Styrene acrylate copolymer，簡稱ASA)，被廣泛使用，原因為其材料擁有高耐衝擊性、良好的機械強度與優良的耐候性。本研究使用田口實驗設計法來規劃實驗後，使用全電式射出成型機依擬訂參數進行射出，再藉由S/N比、灰色關聯分析法進行ASA/FIBER多重機械性質製程條件的最佳化分析，實驗設計方面採用田口方法中的L9直交表，選擇射出壓力、模具溫度、融膠溫度與複合纖維重量百分比為控制因子，每個因子分三水準射出並進行材料試驗，獲得其單一機械品質最佳化後結合灰關聯分析理論做出多重機械性質製程條件的最佳化，借以探討不同重量百分比之玻璃纖維對ASA機械性質的影響(硬度、拉伸、壓痕試驗)，最後使用(SEM、OM)進行表面與破斷面的觀察；(EDS、XRD)進行元素與結構的分析。
實驗結果顯示材料在田口抗拉強度製程最佳化組合為A3B1C1D1且強度依纖維比例提升有線性提升約42%；在硬度與抗壓應力方面製程最佳化組合為A3B2C2D2強度上也有59%的提升，本研究在完成田口法單一品值最佳化後，導入灰關聯分析法並計算出複合材料之抗拉強度與硬度之多重品質最佳化製程參數為A3B1C3D2，其抗拉強度相較原材料強化約39.6%；硬度部分強化約44.8%，另外使用掃描式電子顯微鏡觀(SEM)觀察破斷面，結果顯示材料在加入玻璃纖維後有由韌轉脆的情形，也從表面觀察出其韌性與脆性的特徵組織，並使用能量散射光譜分析儀(EDS)進行破斷面之半定量元素分析，顯示GF/ASA混合後有Si元素的產生，此外經由(XRD)實驗結果顯示ASA為非結晶性材料，且纖維含量增加並不影響其ASA晶相結構並其強化了其機械性質，熔融指數分析結果顯示材料在加入GF後流動性有線性下降趨勢；差式掃描熱量分析結果顯示ASA/GF複合材料，各項熱學溫度:玻璃轉換溫度Tg，在58.78℃到59.77℃為材料Tc溫度，114.66℃到117.35℃可能為其熔點Tm，但因材料為非結晶性材料固熔點不明顯；熱重分析結果顯示ASA/GF材料在加熱至350℃左右開始氣化；在420-430℃失重約42-52%；在450℃時完全氣化並可觀察出其剩餘重量百分比分別為1%、13.8%、20.29%可與高溫灰化結果互相驗證並得出材料中實際的玻纖含量，另外本研究將傅立葉紅外線光譜分析結果顯示並證明本複合材料基材為丙烯腈-苯乙烯-丙烯酸酯共聚物，且加入玻璃纖維後不影響其官能基特徵峰位置。
綜合以上敘述，本研究成功利用田口/灰關聯法研發出高抗拉強度、硬度、低成本(相較碳纖維與奈米碳管複合材)之強化材，並了解其最佳化射出參數應用於廣大射出成型市場。

關鍵字

ASA/ FIBER ； 射出成型 ； 田口實驗法 ； 灰關聯分析理論

並列摘要

Acrylonitrile-styrene-acrylate terpolymer (ASA) material is used widely because of good properties in high impact resistance, good mechanical strength, and good weather resistance. Application of Taguchi-based Gray relational analysis for studying on mechanical properties in different weight percent of the glass fiber hybrid/ ASA by injection molding process . After forming the different levels of weight percent of the glass fiber hybrid / ASA morphology SEM, OM , mechanical properties Hardness, Tensile test, compression test, structure analysis EDS, XRD, MI, TGA, DSC, FTIR.
Experimental results show that the tensile strength of the material Taguchi process optimization combination A3B1C1D1 and increase the percentage of fiber strength by linear lift about 42%; a combination of process optimization in terms of hardness and compressive stress on A3B2C2D2 strength 59% increase the present study after the completion of the Taguchi method to optimize the value of a single product, the import of gray relational analysis and calculate the best quality of multiple process parameters tensile strength and hardness of the composite is A3B1C3D2, strengthen its tensile strength compared to the raw material about 39.6%; hardness of about 44.8% partial reinforcement, fracture surface was observed using SEM showed that the material in the case by the addition of glass fibers turn brittle and tough, but also from its surface observation toughness and brittle tissue characteristics and uses EDS semi-quantitative elemental analysis of fracture surface, showing GF / ASA have produced mixed Si element, in addition to XRD results showed that ASA non-crystalline material, and increase the fiber content does not affect its ASA and its crystalline structure strengthened its mechanical properties. MI showed that the material after the addition of GF liquidity linear downward trend; DSC showed ASA / GF composites, the thermal temperature: Tg, Tc, Tm, but the material is non-crystalline solid material Tm obvious; TGA results display ASA / GF material is heated to about 350 ℃ start gasification; weight loss of about 42-52% at 420-430 ℃; completely vaporized and its remaining weight was observed at 450 ℃ percentage of 1%, 13.8% respectively, 20.29% with a high temperature ashing another positive test results and the actual material obtained glass content, in addition to this study, FTIR analysis showed and proved the present composite substrates is acrylonitrile - styrene - acrylate copolymer, and added glass fiber does not affect the characteristic peak positions of functional groups.

並列關鍵字

ASA/ FIBER ； Injection molding ； Taguchi method ； Gray relational analysis theory

參考文獻

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