臺灣博碩士論文加值系統

本研究以快速原型、快速模具方法，提出一個製作方法簡單、低製作成本之低壓射蠟快速模具製造技術，首先運用田口方法探討低壓射蠟之最佳化製程參數，因為在射蠟製程當中，蠟的溢出量是一個問題。本研究發現，低壓射蠟之蠟溢出量最少之最佳參數為射蠟溫度82 ℃、射蠟時間2秒、射蠟壓力0.6 kgf/cm2、以及矽膠模具預熱溫度60 ℃，影響低壓射蠟之蠟溢出量最少之最大影響因子為射蠟時間73.95 %、期次為射蠟壓力18.27 %。本研究所提出之方法製作13 cm x 13 cm x 4 cm的低壓射蠟模具，可以節省模具總成本約為83 %。

This study uses Rapid prototyping technology, Rapid tooling technology to propose a method for fabricating low-pressure wax injection rapid toolings. The wax spilling is one of the most troublesome problems during wax injection molding process. From the point of view of shorten product development period and reduce cost, the optimal processing conditions in the wax injection molding process were investigated using Taguchi method.
The results of this study, the optimal processing conditions in the wax injection molding process are injection temperature of 82 ℃ , injection time of 2 sec, injection pressure of 0.6 kgf/cm2 and mold temperature of 60 ℃.The experimental results revealed that the most influential factor affecting the weight of spilled wax during wax injection molding process is the injection time, 73.95 %, next is the injection pressure, 18.27 %.
For the low-pressure wax injection rapid toolings with dimensions of 13 cm in length, 13 cm in width, and 4 cm in height, the total manufacturing cost savings about 83 %.

明志科技大學碩士學位論文指導教授推薦書 i
明志科技大學碩士學位論文口試委員會審定書 ii
誌謝 iii
摘要 iv
Abstract v
目錄 vi
表目錄 viii
圖目錄 ix
第一章 緒論 1
1.1 前言 1
1.2 研究動機與目的 3
1.3 論文架構 5
第二章 文獻回顧 6
2.1 快速原型技術之簡介 6
2.2 快速模具技術之簡介 11
2.3 冷卻水路設計之簡介 20
2.4 射蠟製程技術之簡介 21
第三章 實驗規劃與方法 23
3.1 實驗材料 24
3.1.1 矽膠主劑與硬化劑 24
3.1.2 離型劑 25
3.1.3 金屬樹脂 25
3.1.4 環氧樹脂 27
3.1.5 蠟型(K512) 28
3.2 實驗設備 29
3.2.1 數位多段式真空注蠟機 29
3.2.2 uPrint 快速原型系統 30
3.2.3 真空注型機 31
3.2.4 高溫恆溫烤箱 32
3.2.5 銑床 33
3.2.6 超音波清洗機 34
3.2.7 酸鹼值測定計 35
3.2.8 精密電子秤實體圖 36
第四章 運用田口方法探討低壓射蠟之最佳化製程參數 36
4.1 前言 36
4.2 實驗過程 38
4.3 結果與討論 45
4.4 結論 65
第五章 低壓射蠟快速模具研製與應用 66
5.1 前言 66
5.2 實驗過程 66
5.3 結果與討論 83
5.4 結論 86
第六章 結論及未來展望 87
6.1 結論 87
6.2 未來展望 88
參考文獻 91
附錄 100

[1]何志凌，“射出成型模具價格之計算與分析”，中原大學機械工程學系 碩士論文，中華民國九十五年。
[2]滕文傑，“電腦輔助皮革紋理雕刻之研究”，國立中央大學機械工程研究所 碩士論文，中華民國八十九年。
[3]D. V. Rasato and D. V. Rosato,“Injection Molding Handbook”, Van Nostrand Reinhold Company, NY, 1985.
[4]D. King and T. Tansey, "Alternative materials for rapid tooling," J. mater. process. technol., vol. 121, pp. 313-317, Feb. 2002.
[5]C. C. Kuo, "A simple and cost-effective method for fabricating epoxy-based composite mold inserts," Mater. manuf. process., vol. 27, pp. 383-388, Mar. 2012.
[6]C. C. Kuo and Z. Y. Lin, "Development of bridge tooling for fabricating mold inserts of aspheric optical lens," Materialwissenschaft und Werkstofftechnik, vol. 42, pp. 1019-1024, Nov. 2011.
[7]L. Fei and Z. H. Y. Honghui, "Green Manufacturing── the Sustainable Development Model of Modern Manufacturing Industries," CHINA MECHANICAL ENGINEERING, vol. 6, pp. 24, Jun. 1998.
[8]劉芯華，“產品功能導向之綠色設計評估與綠色製造分析”，元智大學工業工程與管理學系 碩士論文，中華民國一百零一年。
[9]W. Zhe-neng, "Green Manufacturing has been the Development Direction of Modern Manufacturing," Equipment Manufacturing Technology, vol. 3, pp. 35, Mar. 2010.
[10]R.K. Jena, C.Y. Yue, Y.C. Lam, P.S. Tang and A. Gupta” Comparison of different molds (epoxy, polymer and silicon) for microfabrication by hot embossing technique,” Sensors and Actuators B: Chemical, vol. 163, Issue 1, pp. 233-241, Mar. 2012
[11]A. Rosochowski and A. Matuszak,” Rapid tooling: the state of the art,” Journal of Materials Processing Technology, vol. 106, no. 1, pp. 191-198, Oct. 2000.
[12]H. Kodama, “Automatic method for fabricating a three-dimensional plastic model with photo-hardening polymer,” Review of scientific Instruments, vol. 52, pp. 1770-1773, Feb. 1981.
[13]陳俊雄，“運用逆向工程於鞋模設計與製造”，大葉大學工業工程系 碩士論文，中華民國九十年。
[14]曾昱晨，“粉末基快速原型系統之材料特性及系統參數最佳化設計之研究”，國立高雄第一科技大學機械與自動化工程系 碩士論文，中華民國九十年。
[15]吳典錡，“快速原型系統切層方法之研究”，國立台灣科技大學高分子工程系 碩士論文，中華民國九十二年。
[16]P. Peyre, Y. Rouchausse, D. Defauchy and G. Régnier, "Experimental and numerical analysis of the selective laser sintering (SLS) of PA12 and PEKK semi-crystalline polymers," Journal of Materials Processing Technology, vol. 225, pp. 326-336, Nov. 2015.
[17]E. O. Olakanmi, R. F. Cochrane and K. W. Dalgarno, "A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties," Progress in Materials Science, vol.74, pp. 401-477, Oct. 2015.
[18]P.-T. Lan, S.-Y. Chou, L.-L. Chen and D. Gemmill, "Determining fabrication orientations for rapid prototyping with Stereolithography apparatus," Computer-Aided Design, vol. 29, pp. 53-62, Jan.1997.
[19]SCOTTISH PLASTICS AND RUBBER ASSOCIATION. [Websites message]. Retrieved from http://www.spra.org.uk/news/201012/lecture-and-demonstration-rapid-prototyping-techniques-plastics-industry
[20]J. Skowyra, K. Pietrzak and M. A. Alhnan, "Fabrication of extended-release patient-tailored prednisolone tablets via fused deposition modelling (FDM) 3D printing," European Journal of Pharmaceutical Sciences, vol. 68, pp. 11-17, Feb. 2015.
[21]Y. Y. Chiu, Y. S. Liao and C. C. Hou, "Automatic fabrication for bridged laminated object manufacturing (LOM) process," Journal of Materials Processing Technology, vol. 140, pp. 179-184, Sep. 2003.
[22]A. Rosochowski and A. Matuszak, "Rapid tooling: the state of the art," J. mater. process. technol., vol. 106, pp. 191-198, Oct. 2000.
[23]C. Chua, K. Hong and S. Ho, "Rapid tooling technology. Part 1. A comparative study," The International Journal of Advanced Manufacturing Technology, vol. 15, pp. 604-608, Jul. 1999.
[24]羅仁權、周治華、謝正一，“快速模具技術之發展現況與未來趨勢”，機械月刊，28卷，第二期，中華民國九十一年。
[25]C. K. Chua, K. F. Leong and Z. H. Liu, "Rapid Tooling in Manufacturing," in Handbook of Manufacturing Engineering and Technology, ed: Springer, pp. 2525-2549,2015
[26]E. Sachs, M. Cima and J. Cornie, "Three-Dimensional Printing: Rapid Tooling and Prototypes Directly from a CAD Model," CIRP Annals - Manufacturing Technology, vol. 39, pp. 201-204, Oct. 1990.
[27]B. Mueller and D. Kochan, "Laminated object manufacturing for rapid tooling and patternmaking in foundry industry," Computers in Industry, vol. 39, pp. 47-53, Jun. 1999.
[28]P. Jacobs, "The effects of random noise shrinkage on rapid tooling accuracy," Materials & Design, vol. 21, pp. 127-136, Apr. 2000.
[29]H. Müller and J. Sladojevic, "Rapid tooling approaches for small lot production of sheet-metal parts," Journal of Materials Processing Technology, vol. 115, pp. 97-103, Aug. 2001.
[30]J. Hänninen, "DMLS moves from rapid tooling to rapid manufacturing," Metal Powder Report, vol. 56, pp. 24-29, Sep. 2001.
[31]A. Simchi, F. Petzoldt and H. Pohl, "On the development of direct metal laser sintering for rapid tooling," Journal of Materials Processing Technology, vol. 141, pp. 319-328, Nov. 2003.
[32]D. King and T. Tansey, "Rapid tooling: selective laser sintering injection tooling," Journal of Materials Processing Technology, vol. 132, pp. 42-48, Jan. 2003.
[33]J. C. Ferreira and N. F. Alves, "Integration of reverse engineering and rapid tooling in foundry technology," Journal of Materials Processing Technology, vol. 142, pp. 374-382, Nov. 2003.
[34]Y. Ding, H. Lan, J. Hong and D. Wu, "An integrated manufacturing system for rapid tooling based on rapid prototyping," Robotics and Computer-Integrated Manufacturing, vol. 20, pp. 281-288, Aug. 2004.
[35]J. Wang, X. P. Wei, P. Christodoulou, and H. Hermanto, "Rapid tooling for zinc spin casting using arc metal spray technology," Journal of Materials Processing Technology, vol. 146, pp. 283-288, Mar. 2004.
[36]S. Rahmati, M. R. Rezaei and J. Akbari, "Design and Manufacture of a Wax Injection Tool for Investment Casting Using Rapid Tooling," Tsinghua Science & Technology, vol. 14, Supplement 1, pp. 108-115, Jun. 2009.
[37]Y. D. Wei, “An implementation study of patternless casting manufacturing for ship 3D modeling,” New Aspects of Fluid Mechanics, Heat Transfer and Environment, pp. 351-357, 2010.
[38]J. Noble, K. Walczak and D. Dornfeld, "Rapid Tooling Injection Molded Prototypes: A Case Study in Artificial Photosynthesis Technology," Procedia CIRP, vol. 14, pp. 251-256, Jun. 2014.
[39]Nagahanumaiah and B. Ravi, "10.13 - Indirect Rapid Tooling," in Comprehensive Materials Processing, S. H. F. B. J. V. T. Yilbas, Ed., ed Oxford: Elsevier, pp. 345-373, Oct. 2014
[40]P. Li, S. Jiang, Y. Yu, J. Yang and Z. Yang, "Biomaterial characteristics and application of silicone rubber and PVA hydrogels mimicked in organ groups for prostate brachytherapy," Journal of the Mechanical Behavior of Biomedical Materials, vol. 49, pp. 220-234, Sep. 2015.
[41]I.J. Catic, “Cavity Temperature-an Important Parameter in the Injection Molding Process”, Polym Eng Sci, vol.19, p.893,1979
[42]H. Ries and Marl,“Preconditions for the Determination of Practically Oriented Shrinkage Values”, Kunststoffe German Plastics, vol. 82, p.50,1992
[43]S. C. Chen and Y. C. Chung, "Numerical simulations of the cyclic, transient mold heat transfer in injection mold cooling process," International Communications in Heat and Mass Transfer, vol. 21, pp. 323-332, May. 1994.
[44]Gerald A. Lavallee and Douglas L. Miller, Golf ball injection mold, US5827548 A
[45]L. Sridhar and K. A. Narh, "The effect of temperature dependent thermal properties on process parameter prediction in injection molding," International Communications in Heat and Mass Transfer, vol. 27, pp. 325-332, Apr. 2000.
[46]Zollner, “Optimised mould temperature control”, Appl.Technol. Inform., p. 1104, 2001
[47]Z.-C. Lin and M.-H. Chou, "Design of the cooling channels in nonrectangular plastic flat injection mold," Journal of Manufacturing Systems, vol. 21, pp. 167-186, Jan. 2002.
[48]D. E. Dimla, M. Camilotto and F. Miani, “Design and optimisation of conformal cooling channels in injection moulding tools”, Journal of Materials Processing Technology, vol. 164-165, pp. 1294-1300, May. 2005
[49]L.-E. Rännar, A. Glad and C.-G. Gustafson, "Efficient cooling with tool inserts manufactured by electron beam melting," Rapid Prototyping Journal, vol. 13, pp. 128-135, Jun. 2007.
[50]L. E. Rännar,“On optimization of injection molding cooling”, Ph.D. Thesis, Engineering Design and Materials, Norwegian University of Science and Technology, Apr. 2008
[51]Y. Wang, K.-M. Yu, C. C. L. Wang and Y. Zhang, "Automatic design of conformal cooling circuits for rapid tooling," Computer-Aided Design, vol. 43, pp. 1001-1010, Aug. 2011.
[52]K. Altaf, A. Majdi Abdul Rani and V. R. Raghavan, "Prototype production and experimental analysis for circular and profiled conformal cooling channels in aluminium filled epoxy injection mould tools," Rapid Prototyping Journal, vol. 19, Iss. 4, pp. 220-229, Apr. 2013.
[53]J. G. Kovács, F. Szabó, N. K. Kovács, A. Suplicz, B. Zink, T. Tábi, et al., "Thermal simulations and measurements for rapid tool inserts in injection molding applications," Applied Thermal Engineering, vol. 85, pp. 44-51, Jun. 2015.
[54]T. S. Hock, P. Christodoulou and P. K. D. V. Yarlagadda, “Experimental Studies on the accuracy of wax patterns used in investment casting”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 217, pp.285-289 ,2003.
[55]S. Rahmati, M. R. Rezaei and J. Akbari, “Design and Manufacture of a Wax Injection Tool for Investment Casting Using Rapid Tooling”, Tsinghua Science & Technology, vol. 14, pp.108-115, Jun. 2009.
[56]W. Bonilla, S. H. Masood and P.Iovenitti, “An Investigation of Wax Patterns for Accuracy Improvement in Investment Cast Parts”, The Internal Journal of Advanced Manufacturing Technology, vol. 18, pp. 348-356 , Sep. 2001.
[57]P. K. D. V. Yarlagadda and R. S. Hock, “Statistical Analysis on Accuracy of Wax Patterns Used in Investment Casting Process”, Journal of Materials Processing Technology, vol. 138, pp. 75-81 ,2003.
[58]S. A. M. Rezavand and A. H. Behravesh, "An experimental investigation on dimensional stability of injected wax patterns of gas turbine blades," Journal of Materials Processing Technology,vol.182, pp.580-587,Feb. 2007.
[59]黃榮明(2011)，精密鑄造射蠟成型尺寸縮水率預測，中原大學機械工程系碩士論文。
[60]H. T. Liu and S. R. Ge, "Fishbone graph fractal description to UHMWPE wear debris boundary," Tribology International, vol. 42, pp. 1624-1628, Dec. 2009.
[61]Y. A. Zhu, Y. C. Dai, D. Chen and W. K. Yuan, "First-principles study of carbon diffusion in bulk nickel during the growth of fishbone-type carbon nanofibers," Carbon, vol. 45, pp. 21-27, Jan. 2007.
[62]T. Worch, L. Dooley, J. F. Meullenet and P. H. Punter, "Comparison of PLS dummy variables and Fishbone method to determine optimal product characteristics from ideal profiles," Food quality and preference, vol. 21, pp. 1077-1087, Dec. 2010.
[63]A. Howladar and D. Cavallucci, "Analysing complex engineering situations through problem graph," Procedia Engineering, vol. 9, pp. 18-29, May. 2011.
[64]K. N. Ballantyne, R. A. van Oorschot, and R. J. Mitchell, "Reduce optimisation time and effort: Taguchi experimental design methods," Forensic Science International: Genetics Supplement Series, vol. 1, pp. 7-8, Aug. 2008.
[65]S. S. Mahapatra and A. Patnaik, "Study on mechanical and erosion wear behavior of hybrid composites using Taguchi experimental design," Materials & Design, vol. 30, pp. 2791-2801, Sep. 2009.
[66]E. Barrado, M. Vega, R. Pardo, P. Grande, and J. L. Del Valle, "Optimisation of a purification method for metal-containing wastewater by use of a Taguchi experimental design," Water Research, vol. 30, pp. 2309-2314, Oct. 1996.
[67]李輝煌。2000。田口方法：品質設計的原理與實務。初版。台北：高立。
[68]黎正中。1993。穩健設計之品質工程。台北：台北圖書。
[69]吳復強。1992。田口品質工程。初版。台北：全威。
[70]C. C. Kuo, C. Y. Lin and X. Z. Wu,“ Development of an adjustable mold box for making silicone rubber mold,” 2010 IEEE International Conference on Industrial Engineering and Engineering Management, pp.762-766, Dec. 2010.
[71]S. Pattnaik, D. Karunakar and P. Jha, "Influence of injection process parameters on dimensional stability of wax patterns made by the lost wax process using Taguchi approach," Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials Design and Applications, p. 1464420712451807, 2012.
[72]M. Horacek and S. Lubos, "Influence of injection parameters to the dimensional stability of wax patterns," Proceedings of the Ninth World Conference on Investment Casting, San Francisco, California, USA (1996), pp. 1-20
[73]A. Sabau and S. Viswanathan, "Prediction of wax pattern dimensions in investment casting," Transactions-American Foundrymens society, vol. 1, pp. 733-746, 2002.
[74]D. Wang, B. He, F. Li and B. Sun, "Numerical simulation of the wax injection process for investment casting," Materials and Manufacturing Processes, vol. 28, no.6, pp. 220-224, Feb. 2013.
[75]Y. T. Liu, W. C. Chang and Y. Yamagata, "A study on optimal compensation cutting for an aspheric surface using the Taguchi method," CIRP Journal of Manufacturing Science and Technology, vol. 3, pp. 40-48, Apr. 2010.
[76]S. Rahmati, J. Akbari and E. Barati, "Dimensional accuracy analysis of wax patterns created by RTV silicone rubber molding using the Taguchi approach," Rapid Prototyping Journal, vol. 13, pp. 115-122, Feb. 2007.
[77]C. C. Kuo, “Solidification velocity in liquid silicon during excimer laser crystallization,” Applied Physics A: Materials Science & Processing, vol. 95, pp. 573-578, May. 2009.
[78]P. Ioannis and Z. Qin, ”Optimization of Injection Molding Design”, Polymer Engineering and Science, vol.30, no.15, pp. 875, Aug. 1990