本文主要是研究機車後架在塑膠射出成形的生產過程中，如何以 CAE 模流分析瞭解各個成形因子對產品翹曲變形量的影響，以及各個成形因子對產品翹曲變形的反應程度及重要性，並找出產生翹曲的原因，改善成形因子，控制產品的翹曲變形量，以達成產品翹曲最小化的目的。

　　本文的研究方法主要是使用「田口式實驗設計法」進行規劃，並選擇比較具有影響力的因子作為控制因子。實驗流程分為「模具設計優化之流程」與「成形條件優化之流程」兩大流程。模具設計優化的控制因子，有「流道尺寸」、「澆口尺寸」、「冷卻水路」三個因子；接續是成形條件優化的控制因子，有「模具溫度」、「熔膠溫度」、「射出時間」、「保壓壓力」、「保壓時間」及「保壓切換點」六個因子。

　　本研究的結果模具設計優化能降低剪切率、降低翹曲變形量、縮短
冷卻時間。而成形條件優化的控制因子，影響最大的是保壓壓力。

　　The purpose of this research is mainly investigated to minimize the warpage of the Motorcycle Carrier by optimum molding conditionc and mold design. The technology of Computer Aided Engineering (CAE) and the Taguchi method are used to simulate and to choose more useful control factors of experiments for the reduction of warpage.
　　The procedures of this experiment include two stages; driftage of molding conditions and driftage of the mold design. In the driftage of mold design, the size of gate and the size of square are modified to reduce the shear rate and shear stress. The cooling system were modified to improve the cooling efficiency and reduce the cycle time of the injection process. In the driftage of molding conditions, six conditions such as injection time、packing pressure、packing time、melt temperature、mold temperature、V/P switch point are taken as control factors for Taguchi method to find out the optimum combination that can minimize the warpage of the Motorcycle Carrier.
　　The result of this research are showed that driftage of molding conditions and driftage of the mold design can reduce shear rate、shear stress、warpage and cooling time, and the most important control factors for reduction of warpage is the packing pressure.

中文摘要 i
英文摘要 ii
誌謝 iii
目錄 iv
表目錄 vi
圖目錄 vii
第一章 緒論 1
1.1 研究動機與目的 1
1.2 文獻回顧 3
1.3 論文架構 6
第二章 射出成形基本原理 7
2.1 射出成形 7
2.2 射出成形品的翹曲變形 9
2.3 影響射出成形品翹曲變形的因素 9
2.3.1 成品設計之影響 9
2.3.2 模具設計之影響 10
2.3.3 成形技術之影響 11
第三章 田口式實驗計劃法 16
3.1 田口實驗法簡介 16
3.2 田口實驗法步驟 17
3.3 田口信號雜音比(S/N比) 20
3.4 變異分析(Analysis of Variance, ANOVA) 22
第四章 實驗設備與規劃 25
4.1 實驗設備 25
4.2 實驗方法 28
4.3 實驗步驟及流程 28
4.4 軟體前置處理過程 28
4.5 產品問題探討 31
4.6 模具設計優化 32
4.7 成形條件設定對產品翹曲之影響規劃 33
4.8 最佳化成形條件之實驗規劃 34
第五章 實驗結果與討論 50
5.1 模具設計優化的結果與討論 50
5.2 成形條件設定對產品翹曲之影響 51
5.3 最佳化成形條件之實驗結果 52
第六章 結論與建議 65
6.1 結論 65
6.2 建議 66
參考文獻 67
簡歷 70

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