臺灣博碩士論文加值系統

因澆口位置會決定融膠的流動方向與平衡性，不當的設計往往造成無法彌補的缺陷，所以流動平衡之澆口位置一直是塑膠射出成型模模具設計中的一個重要關鍵。本文採用降低流阻之觀念針對不同幾何模型、網格長度、塑膠材料(ABS+PC、PP、HDPE)進行澆口位置最佳化之搜尋與探討，以期達到流動平衡之充填過程。結果顯示澆口位置經過最佳化後能有效地改善充填結束時過保壓、高壁面剪應力與溫度分布不均等影響塑件品質之缺陷。本文在求得澆口位置最佳化後，另再擇一算例進一步採用田口法、遺傳演算法、模擬退火法、類神經網路與反應曲面法等方法，以單獨或偶合的方式探討模溫、融溫、射出時間、保壓時間與保壓壓力等五個製程參數之最佳化組合。結果顯示各最佳化方法均能有效降低塑件翹曲；田口法僅需少量的模擬即可獲得滿意的結果，遺傳演算法與模擬退火法結合類神經網路與反應曲面法能再微調製程參數，進一步提升產品之品質。

Gate location has the direct effect on the melt flow direction and balance,and improper design will produce inevitable defects.Therefore, the gate location with flow balance is one of the important key points of mold design of plastic injection molding. This study adopts flow resistance concept in the light of different geometric shape, mesh size, materials (ABS+PC, PP, HDPE) to explore the optimal gate location to reach the filling process with the flow balance. The results show that the optimal gate location is able to effectively improve the over-packing, high wall shear stress and disproportionate temperature distribution which will influence plastic part quality. After the optimal gate location being obtained, one case was further studied by using Taguchi method, genetic algorithm, simulated annealing method, artificial neural network and response surface method, with single or hybrid mode to find the optimal molding parameter setting such as mold temperature, melt temperature, injection time, packing time and packing pressure. It is revealed that the optimal method is able to effectively reduce plastic part warpage. Taguchi method can achieve satisfactory result with small relatively amount of simulations. The genetic algorithm and simulated annealing method couples with artificial neural network or response surface method have the advantage to tune the processing parameters,and to promote product quality.

中文摘要………………………………………………………………I
英文摘要………………………………………………………………II
致謝……………………………………………………………………III
目錄.……...…………………………………………………………IV
圖表索引………………………………………………………………VX
第一章 緒論…………………………………………………………1
1.1 前言…………………………………………………………. 1
1.2 文獻回顧……………………………………..………..…….3
1.3 研究動機與目標……………..………...……………..…..7
第二章 澆口位置最佳化步驟與流程………………………………9
2.1 最佳化之軟體設定與分析……………………..………… 9
2.1.1 分析模型之建立……………………………………... 9
2.1.2 分析材料選擇……………….……………………….. 10
2.1.3 澆口位置最佳化過程之成型參數設定……………... 10
2.2 澆口位置最佳化流程……………………………….........10
2.2.1 定義澆口位置最佳化……………………………...... 10
2.2.2 壓力梯度法之澆口位置最佳化流程……….……...... 11
2.2.3 以形心位置為起始點之澆口位置最佳化…….…….. 12
第三章 最佳化方法概述……………………………..………..…13
3.1 遺傳演算法…………..…………………………………….. 13
3.1.1 遺傳演算法收斂性………………………………….. 14
3.2模擬退火法……………………….…………………………. 14
3.2.1模擬退火法流程………………………………..…….. 15
3.2.2 Metropolis抽樣演算法………………………..…….. 16
3.3 田口品質工程..…………………………………..………… 16
3.3.1 田口法參數設計…………………………….……….. 17
3.3.2 品質特性種類……..……………....…………………. 18
3.3.3 直交表..…….…..……………………………..…...… 18
3.4 類神經網路………..…………………………..…………… 20
3.4.1類神經網路運作過程….………...…………………… 20
3.4.2 倒傳遞類神經網路架構……………………………... 20
3.4.3倒傳遞網路神經元模型..……………………..……… 21
3.5 反應曲面法..……………………………..………………… 22
3.5.1 反應曲面法數學模式…………………………..……. 23
3.5.2 反應曲面法最佳化過程……………………………... 24
第四章 模擬軟體與製程參數最佳化方法….…..……………… 25
4.1 模流分析……..……………………………..……………… 25
4.1.1前處理…..…………………………………………….. 25
4.1.2 模擬分析形式之選擇…..……………………………. 26
4.1.3 後處理……..…………………………………………. 26
4.2 製程參數最佳化之塑件收縮定義與量測………………. 27
4.3 JMP 5.1軟體與倒傳遞類神經網路…………………………. 27
4.3.1 類神經網路訓練資料之建立………………………... 28
4.3.2 類神經網路之選取與設定………………..…………. 28
4.4 反應曲面法方程式…………………..……………………...28
4.5 田口法參數最佳化………………..………………………...28
4.6 遺傳演算法參數最佳化………………..…………………...29
4.7 類神經網路與反應曲面法結合模擬退火法之參數最佳化. 30
第五章 結果與討論…………………………………………………32
5.1 起始位置對澆口位置最佳化搜尋結果之影響……………. 32
5.2 網格長度對澆口位置最佳化搜尋結果之影響……………. 34
5.3 不同塑膠材料對澆口位置最佳化之影響…………………. 36
5.4 澆口位置對塑件品質之影響………………………………. 38
5.4.1 澆口位置對過保壓現象之影響……………………... 38
5.4.2 澆口位置對壁面剪應力之影響……………………... 39
5.4.3 澆口位置對塑件最大溫差之影響…………………... 39
5.5 製程參數最佳化……………………………………………. 40
5.5.1 未製程參數最佳化之塑件翹曲結果………………... 40
5.5.2 田口法最佳化製程參數組合………………………... 41
5.5.3 遺傳演算法之製程參數最佳化結果………………... 42
5.5.4 模擬退火法之製程參數最佳化結果……...……...…. 44
5.5.5 各種最佳化方法結果與比較………………………... 45
5.5.6 類神經網路與反應曲面法尋求之近似函數比較…... 46
5.5.7 遺傳演算法、模擬退火法與田口法之比較………… 47
5.5.8 製程參數對塑件之影響……………………………... 48
第六章結論與建議……………………………………………………50
6.1 結論……………………………………………………………50
6.2 建議…………………………………………………………. 51
參考文獻……….……………………………………………………107
附錄A:射出成形之理論背景…………………………………………112
附錄B:類神經網路之數學模式………………………………………117
附錄C: 形心(Centroid)之計算……….……………………………125
附錄D:類神經網路與反應曲面方程式………………………………127
作者簡介………………………………………………………………130

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