臺灣博碩士論文加值系統

製品的幾何精度與強度是陶瓷射出成形元件之兩個首要的基本要求。在幾何形狀複雜的陶瓷元件射出成形製程中，收縮率是左右製品的尺寸與形狀精度的主要因素，甚至由於不良的收縮率分佈而會導致產生斷裂等缺陷，而陶瓷製品的收縮量亦與脫脂、燒結過程後的機械強度有密切的關係。造成收縮率的差異，其原因與陶瓷粉末的性質、混合物材料的流變特性等因素有關。
本研究利用具有銷孔及90o彎角幾何形狀的模具來進行陶瓷粉末射出成形實驗，探討氧化鋯粉末與不同的黏結劑混合後，在不同的射速及射壓的成形條件下的結果，並觀測各個階段的外觀缺陷、收縮率與機械強度上的影響。方法上，藉由CCD顯微鏡及數位游標尺分別來量測生胚及燒結體各方向的尺寸並計算出收縮率，且觀察成形至燒結過程中產生的缺陷，最後亦測量燒結完成品的硬度、密度及三點彎曲強度以得知收縮率與機械強度的關係。
研究結果顯示，在射出成形中，具有銷孔及90o彎角幾何形狀的模具所產生的擾流及剪切作用，改變了陶瓷混合物內的粉粒配向，導致燒結後的銷孔及90o彎角處之收縮量改變，以及後續測試的抗彎強度變小。此外，收縮率與緻密度的關係直接反應於製品的抗彎強度。

Geometric precision and strength are two primary requirements for ceramic injection molded components. In the process of geometrically complex ceramic injection molding, shrinkage is one of the most important factors which affects dimensional precision and loss of shape. Non-uniform shrinkage will lead to defects such as fracture. In addition, shrinkage also has a closely relationship with mechanical strength of ceramics after debinding and sintering processes. The variation of shrinkage was related to the character of ceramic powder and the rheological properties of ceramic mixtures.
In this study, we used the geometrically L-type mold with a pin hole to conduct the ceramic injection molding experiment, investigating the phenomenon of the zirconic powder mixed with different binder systems under different injection speed and injection pressure. At the same time, we observed the defects of shape and shrinkage on the various molding stages, which impacts on mechanical strength. We measured dimensions of the green body and sintered specimens in three orthogonal directions by CCD microscope and digital vernier caliper respectively and then calculated the shrinkage rate. Furthermore, we observed defects during injection molding, debinding, and sintering processes, and finally measured the hardness, the density, and the flexural strength of sintered specimens. Through this, we obtained the relationship between shrinkage and mechanical strength.
Experimental results indicated that there were turbulent flow and shear effect resulted from the L-type mold with a pin hole during ceramic injection molding. They not only changed particle orientation of the ceramic mixtures, but also brought about changes of sintered shrinkage in a pin hole and L-type position. As the following test, we found flexural strength become smaller. Besides, the relationship of shrinkage and densification directly affected flexural strength of ceramic products.

中文摘要 i
英文摘要 ii
誌謝 iv
目錄 v
表目錄 vii
圖目錄 viii
第一章 緒論 1
1-1前言 1
1-2研究動機與目的 2
1-3文獻探討 3
1-4研究方法 6
第二章 陶瓷粉末射出成形製程及其理論基礎 9
2-1陶瓷粉末射出成形製程概述 9
2-2混練(Mixing)與黏結劑系統(Binder Systems) 9
2-2-1黏結劑各組成的功能 9
2-2-2黏結劑的選擇 10
2-2-3混練的影響 11
2-3射出成形(Injection Molding) 12
2-4脫脂(Debinding) 12
2-5燒結(Sintering) 13
第三章 扁平狀陶瓷件射出成形的收縮特性實驗 15
3-1實驗目的與規劃 15
3-1-1實驗目的 15
3-1-2實驗規劃 15
3-2實驗材料與實驗裝置 16
3-2-1實驗材料 16
3-2-2實驗設備 17
3-3實驗方法 18
3-3-1配製陶瓷粉末與黏結劑 18
3-3-2基本流路充填實驗參數的選定 19
3-3-3脫脂條件的決定 19
3-3-4燒結條件的決定 20
3-4收縮量測與收縮百分比計算 20
3-4-1收縮量測方法 20
3-4-2收縮百分比的計算方法 21
3-5熱重分析 21
3-6流變特性之量測 22
3-7密度分析 22
3-8硬度量測 22
3-9三點彎曲試驗 23
第四章 實驗結果與討論 47
4-1各階段製程之結果 47
4-1-1各階段製程之成品及其缺陷 47
4-1-2 收縮率的結果與分析 49
4-2密度的量測結果 51
4-3硬度的量測結果 51
4-4三點彎曲測試結果 51
第五章 結論與未來展望 85
5-1結論 85
5-2未來展望 88
參考文獻 89
附錄A 93
附錄B 115

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