臺灣博碩士論文加值系統

本研究目的主要是探討成品在模穴內受到模內干涉效應位移影響之變形，並利用可視化技術即時觀察融膠在模穴內流動的行為及收縮的情形。精密穿孔陣列可應用於光通訊及光電元件，孔之真圓度及位置精度極為重要，卻可能因模內干涉而影響呈非等向性收縮，值得研究。主要研究內容包括可視化模具設計、模流觀測分析及利用田口品質工程做射出成型條件最佳化之決定。本文利用田口實驗方法及模擬分析討論不同模具溫度、料溫及射出速度等參數對成品收縮翹曲之影響，皆發現模具溫度為主要影響成型品收縮之參數。
本研究藉由可視化模具搭配內視鏡觀察系統，成功的即時觀察在射出成型過程中模內干涉對陣列圓孔所產生的變形；另外利用高速攝影機拍攝塑料在模內的流動波前，並與模擬相比較，發現兩者的流動波前大致上是相吻合的。
在本研究中亦比較模內干涉成型及無模內干涉成型成品圓孔直徑之尺寸，經由模擬與實驗分析發現，在兩種成型法之圓孔直徑尺寸流動X方向皆比Y方向大，並且以無模內干涉成型之成型品收縮量較大，與模擬分析相符合。經由光彈儀量測發現，無模內干涉成型方式之成品殘留應力較有模內干涉成型方式的殘留應力小，且殘留應力分佈較均勻。
本文利用模流分析軟體找出可靠的射出成型參數與較佳之模具設計，縮短模具製造與設計的時間，並與實驗相互驗證，進一步建立可視化模具之觀測技術，以了解成型過程中所產生的問題與缺陷。

The objective of this study is to use a real time visualization technique to observe the effects of in-mold constraint on the shrinkage of a through hole array. Such a hole array can used in optical communication or optoelectronics applications. Precision control of roundness and position accuracy of the hole arrays are extremely important and directly related to diameter and pitch shrinkage of the hole arrays. In order to have through holes, pins are assembled within the cavity and result in anisotropic shrinkage of the through holes, or so called in-mold constraint shrinkage. To better understand the phenomena, a special designed mold was made to meet this attention. The molded part is a plate of 1mm thick. It has 3x3 through holes of 3mm in diameter. A endoscope behind a transparent quartz block was mounted upon the mold cavity to observe the live shrinkage inside the mold cavity. The melt front advancement can be captured by a high speed camera, respectively.
In order to understand the effects of different processing conditions on the shrinkage of sampled hole diameter, Taguchi’s design method of experiments was applied to obtain meaningful results in less times of experiments. The numerical simulation results have shown the mold temperature is the most significant factor to holes’ shrinkage. Thermal shrinkage is about five times larger than the in-mold constraint shrinkage. The real time visualization helps us to observe live shrinkage in both with and without in-mold constraint cases. The pins inside the mold will stop the plastic to shrink and make the holes become elliptic during the in mold cooling. This makes that the dimension along the flow direction (x-direction) was found larger than the one in y-direction. Therefore lower shrinkage was found in the with in-mold constraint products. The in-mold constraint will result in higher residual stresses from the photo-elasticity measurement. It is because the polymer material is restricted to shrink and result in higher internal stresses within the molded parts.
The presented work has increase our understanding of the shrinkage with and without in-mold constraint for molding a plate with through hole array. Future work may be extended to the cases of injection molded short fiber reinforced composites.

中文摘要-------------------------------------------------------------------------------------
英文摘要-------------------------------------------------------------------------------------
誌謝-------------------------------------------------------------------------------------------
目錄-------------------------------------------------------------------------------------------
表目錄----------------------------------------------------------------------------------------
圖目錄----------------------------------------------------------------------------------------
符號說明-------------------------------------------------------------------------------------

第一章 緒論--------------------------------------------------------------------------------
1-1前言----------------------------------------------------------------------------------
1-2研究動機與目的-------------------------------------------------------------------
1-3傳統射出成型----------------------------------------------------------------------
1-4精密微射出成型-------------------------------------------------------------------
1-5文獻回顧----------------------------------------------------------------------------

第二章 研究問題描述--------------------------------------------------------------------
2-1研究方向----------------------------------------------------------------------------
2-2模流分析----------------------------------------------------------------------------
2-3影響射出成型品收縮與翹曲變形的因素-------------------------------------
2-3-1 模具設計之影響-----------------------------------------------------------
2-3-2 成品設計之影響-----------------------------------------------------------
2-3-3 成型技術之影響-----------------------------------------------------------
2-3-4 殘留應力的影響-----------------------------------------------------------
2-3-5 塑件的收縮-----------------------------------------------------------------

第三章 理論分析--------------------------------------------------------------------------
3-1引言----------------------------------------------------------------------------------
3-2熱傳之統制方程式----------------------------------------------------------------
3-3保壓與冷卻時間之分析----------------------------------------------------------
3-4田口式品質工程-------------------------------------------------------------------
3-4-1望小特性的損失函數------------------------------------------------------
3-4-2信號雜訊比------------------------------------------------------------------
3-4-3直交表應用------------------------------------------------------------------
3-4-4數據分析流程---------------------------------------------------------------
3-5應力與光學之關係---------------------------------------------------------------
3-5-1應力與雙折射率------------------------------------------------------------
3-5-2雙折射率差值理論---------------------------------------------------------
3-5-3受應力平板在圓偏振儀之效應------------------------------------------
3-5-4數位光彈理論---------------------------------------------------------------

第四章 實驗設備與方法-----------------------------------------------------------------
4-1實驗設備----------------------------------------------------------------------------
4-1-1伺服油壓閉迴路控制射出成型機規格---------------------------------
4-1-2全電式射出成型機規格---------------------------------------------------
4-1-3成型品及實驗模具設計---------------------------------------------------
4-1-4油壓動力單元系統與射出成型機之連結------------------------------
4-1-5觀察設備---------------------------------------------------------------------
4-2塑膠原料規格----------------------------------------------------------------------
4-3模流分析步驟----------------------------------------------------------------------
4-4實驗方法與步驟-------------------------------------------------------------------
4-4-1 流動觀察實驗--------------------------------------------------------------
4-4-2 陣列孔收縮觀察實驗-----------------------------------------------------
4-4-3 射出成型實驗----------------------------------------------------------
4-5成型品尺寸之量測----------------------------------------------------------------
4-6殘留應力之量測-------------------------------------------------------------------

第五章 實驗結果與討論-----------------------------------------------------------------
5-1射出成型之CAE模擬-----------------------------------------------------------
5-2射出成型-田口實驗分析---------------------------------------------------------
5-3收縮翹曲之模擬-------------------------------------------------------------------
5-4流動觀察實驗----------------------------------------------------------------------
5-5 CAE流動波前之模擬------------------------------------------------------------
5-6模內干涉對孔陣列收縮之可視化實驗----------------------------------------
5-7無模內干涉對孔陣列收縮之可視化實驗-------------------------------------
5-8模內干涉對孔陣列收縮之效應-------------------------------------------------
5-9模內干涉與無模內干涉之模擬分析-------------------------------------------
5-10模內干涉與無模內干涉成型應力分析--------------------------------------

第六章 結論與建議-----------------------------------------------------------------------
6-1結論----------------------------------------------------------------------------------
6-2建議----------------------------------------------------------------------------------

參考文獻-------------------------------------------------------------------------------------
附錄 實驗設備及模具圖-----------------------------------------------------------------
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