臺灣博碩士論文加值系統

工程、商學及管理學門裡所談論的最佳化(Optimization)都需要先建模(modeling)，然而在諸多製程上，建模是費時且繁雜的工作，在本文中，分別使用可拓理論與灰色理論，在製程設計上，除了對於此兩個理論做一剖析外，並作一連串用於生產線製程最佳化設計的個案探討。
本研究以短玻璃纖維強化聚碳酸酯材料，探討不同射出成型條件如充填時間、融膠溫度、模具溫度與保壓壓力下之纖維排列方向對衝擊疲勞特性影響。針對射出成型製程最佳化設計的研究，以短纖維強化聚合碳酸酯複合材料為材料，以衝擊疲勞試片為射出成型的研究標的。以往，在調整相關射出參數時需要進行一連串試誤法，常需耗時且不易得到最佳的設計，又沒考慮到相關射出參數的交互作用，不但廢時又費力，更何況在高分子複合材料領域更困難。故本文採用可拓理論、灰色理論在製程最佳化的研究下，可以在最少實驗次數下，求得最佳化的製程條件組合。再用C-MOLD模擬分析取得實驗數據，以表皮層纖維排列厚度為品質特性的評量指標，求取射出成型的最佳製程條件，與可拓理論、灰色理論的製程最佳化結果做一驗證，結果有一致的趨勢。
成型條件為填充時間5秒、融膠溫度270℃、模具溫度80℃與保壓壓力100%下，短玻璃纖維強化聚碳酸酯複合材料具有最佳的衝擊疲勞強度，其強度隨著強化纖維的平行於衝擊疲勞方向之纖維排列厚度增加而增加，此一製程最佳化的發現，實為本文的最大貢獻。

The optimization in the engineering and management fields needs modeling. However, as to the manufacturing process, modeling will take lot of time and inconveniency. In this dissertation, we separated use the Extensional Set Theory and Grey System Theory in the manufacturing process optimization of injection molding process in impact fatigue specimen of short glass fiber reinforced polycarbonate composites.

In this dissertation, the effects of fiber orientation on impact fatigue of polycarbonate composites reinforced with short glass fiber are studied. The specimens were prepared under various injection molding conditions, such as filling time, melting temperature, mold temperature and holding pressure. For the design research of the manufacturing process optimization in the injection molding, we use the short glass fiber reinforced polycarbonate composites materials to make the impact fatigue specimen being the goal of research. This method can replace the traditional 「change-one-parameter-at-a-time」 approach which is very inefficient, costly, time consuming and almost impracticable to yield an optimum solution. In the mean time, the prediction of fiber orientation microstructures were examined with a C-Mold software to determine the short glass fiber orientation and share layer thickness to check the results of CAE simulation. The results indicated that two distinct layers (skin layer and core layer) are observed from surface to core at various injection molding conditions. The short glass fiber orientation is perpendicular to the melt flow direction in core layer, but it has the opposite direction in skin layer. From the CAE analysis, we have gotten opposite process parameters to obtain the thicken skin layer that was our target. We simultaneously use the standard specimen of impact fatigue testing to study. It will be better when the fiber direction is parallel to external load. So, to obtain the thickest skin layer is our target. The results indicate that the most important control factor is only the filling time, the others can be neglected. That is completely different form the impact fatigue specimen at the same processing conditions in the previous study. In the same way, we use the Gray System Theory and the Extensional Set Theory to replace the Experimental Design method of Taguchi, we found the results of both are nearly the same.

As to the injection molding conditions, to obtain the best strength (the optimal fiber orientation) were filling time 5s, melting temperature 270℃, mold temperature 80℃ and holding pressure 100%. The addition of short glass fiber to the polycarbonate can effectively increase the strength. The trend of strength is in good agreement with the layer thickness in which the fiber orientation is parallel to the melting polymer direction. This creation of manufacturing process optimization is really the largest contribution in this dissertation.

目錄
摘要
Abstract
目錄
圖目錄
表目錄
第一章 緒論
1.1 前言
1.2 文獻回顧
1.2.1 短玻璃纖維聚碳酸酯複合材料
1.2.2 射出成型與衝擊疲勞試片
1.2.3 可拓理論
1.2.4 層次分析法
1.2.5 灰色理論
1.2.6 泛朦七系
1.3 研究動機
第二章 相關理論與應用方法
2.1 可拓理論
2.1.1 物元
2.1.2 可拓集合
2.1.3 關聯函數
2.1.4 可拓關係
2.1.5 優度評價方法
2.1.6 優度評價法步驟
2.2 AHP的一致性分析
2.2.1 層次分析法的基本原理
2.2.2 層次分析法的步驟
2.3 灰色理論
2.3.1 灰關聯空間
2.3.2 序列比較性
2.3.3 灰關聯生成方式
2.3.4 效果測度法
2.3.5 灰關聯測度的四項公理
2.3.6 灰關聯測度
2.3.7 灰關聯係數
2.3.8 灰關聯度
2.3.9 灰關聯序
2.3.10 灰關聯矩陣
第三章 實例探討
3.1 實驗設計法的目標與準則的選擇
3.1.1 決定研究目標(決定品質特性)
3.1.2 方案與參數(準則)的選擇
3.2 實驗程序
3.2.1 實驗材料
3.2.2 模具設計
3.2.3 成型條件設計
3.3 用C-MOLD模擬分析實驗量測值(水準)
3.4 可拓理論於製程最佳化分析與實驗設計法的模型建立
3.4.1 直交表
3.4.2 建立物元及衡量條件集
3.4.3 確定權係數
3.4.4 建立關聯函數及計算合格度
3.4.5 優度計算及排序
3.5 灰色理論於製程最佳化分析與實驗設計法的模型建立
3.5.1 灰色關聯分析模型
3.5.2 灰色關聯分析的實驗方案
3.5.3 構造模式指標列
3.6 用C-MOLD模擬分析表皮層厚度
3.7 結果與討論
第四章 研究結論
第五章 結論與未來展望
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