臺灣博碩士論文加值系統

薄殼射出成型是3C產業上相當廣泛的應用技術，對成品外觀表面之要求非常嚴格，製作薄殼產品時更常因為厚度之因素造成成型上之困難，甚或造成整體嚴重收縮和翹曲等外觀瑕疵，所以降低或消除翹曲變形便成為薄殼射出成型技術上一大挑戰。
為了解薄殼射出成型品之翹曲變形問題，本文嘗試研究在不同材料及在不同厚度下之薄殼射出成形，以了解造成翹曲或變形的最大因素。本文採用光電式掃描儀來量測成形品之幾何變形以研究其翹曲變形問題。利用模穴壓力量測技術來實際量測進澆口及幾何中點位置處之射出壓力及熔膠溫度值，並與模流分析結果做一比較。同時本文採用田口式直交表來分析降低翹曲變形之最佳製程條件。由本文之研究發現，材料ABS、PC、PP在相同的厚度下，材料PC量測翹曲值較小，材料PP翹曲量最大，材料ABS翹曲變形量介於PC及PP間，在改變厚度後，材料PC只能成形2mm及1mm厚度，而材料ABS在0.5mm厚度下無法成形，所以厚度薄成形困難，實際射出與模擬結果得；為降低翹曲變形，不同塑膠原料在不同厚度下有不同最大影響因子，壓力量測值也隨厚度變薄而增大，材料ABS與PP量測模穴內部壓力時，模穴壓力小翹曲量小。

Thin wall injection molding is one of the key manufacturing technologies for 3C products. Not only the product appearance but also the manufacturing difficulties due to the thickness of plastic wall dominates the successful of thin wall injection molding. Hence, to eliminate or to reduce the warpage becomes one of the major challenge regarding to this technology .
For exploring the warpage problem ,The injection of the plastic parts by a specially designed mold with adjustable cavity thickness is adopted .To measure the physical deformation of injected parts ,a optical scanning instrument is used to show the variations of geometrical dimension to the design . Cavity pressure sensors are embedded into the mold to detest the cavity pressure and melt temperature value. Taguchi method is implemented to find out the optimum processing condition for lowest warpage . The researching result show , with the same thickness , PC parts will have the smallest capacity and PP parts will have the largest one within these 3 materials . If thickness is changed , PC plastic can only be molded in 1mm and 2mm case . However , ABS plastic can not be molded in the 0.5mm case . The cavity pressure is increased once the thickness is decreased . Comparing the simulation to experiments show . There are different greatest influence factors in order to reduce the plastic materials out of shape , different of warping under different thickness, the pressure amount examining value becomes thin and increases different materials with the thickness too there are its warping different parameters of influence under different thickness, when ABS and PP amount examine the pressure within the mould cave , the little warping amount of cave pressure of the mould is little.

目錄
誌謝……………………………………………………………………………………I
中文摘要………………………………………………………………………………II
ABSTRACT……………………………………………………………………………III
目錄……………………………………………………………………………………IV
表目錄………………………………………………………………………………VII
圖目錄………………………………………………………………………………XI
第一章 序論……………………………………………………………………………1
1-1 前言…………………………………………………………………………1
1-2 射出成型製程簡介…………………………………………………………2
1-3 薄殼射出成型………………………………………………………………4
1-4 文獻回顧……………………………………………………………………6
1-5 研究動機與目的……………………………………………………………8
1-6 研究方法……………………………………………………………………9
第二章 實驗設備與步驟………………………………………………………10
2-1 實驗設備……………………………………………………………………10
2-1-1射出成型機…………………………………………………………10
2-1-2 模溫控制機…………………………………………………………11
2-1-3 烘料機………………………………………………………………12
2-1-4 模具…………………………………………………………………13
2-1-5 壓電式壓力及溫度感測器…………………………………………14
2-1-6 資料擷取裝置………………………………………………………15
2-1-7 逆向工程雷射量測系統……………………………………………15
2-2 實驗材料……………………………………………………………………17
2-2-1丙烯腈、丁二烯和苯乙烯三種單體的聚合物………………………17
2-2-2 聚碳酸酯樹脂………………………………………………………18
2-2-3 聚丙烯………………………………………………………………19
2-4 實驗步驟 ………………………………………………………………20
第三章 實驗設計與模擬分析…………………………………………………22
3-1塑膠射出成形之流變學…………………………………………………22
3-2實驗設計………………………………………………………………25
3-2-1田口實驗計畫法簡介…………………………………………………25
3-2-2 田口方法的步驟……………………………………………………26
3-2-3 變異分析(Analysis of Variance， ANOVA)………………………28
3-3模擬分析……………………………………………………………………29
3-3-1 Moldflow簡介………………………………………………………29
3-3-2計算模型………………………………………………………………29
3-3-3 參數設定…………………………………………………………31
3-4雷射掃瞄技術量測翹曲……………………………………………………35
第四章 結果與討論…………………………………………………………………37
4-1田口實驗設計………………………………………………………………37
4-1-1選定品質特性………………………………………………………37
4-1-2判定品質特性之理想機能……………………………………………37
4-1-3選定控制因子與直交表……………………………………………37
4-1-4干擾因子策略…………………………………………………………38
4-2 CAE模擬分析翹曲變形……………………………………………………40
4-2-1 田口實驗計劃法-模擬分析翹曲變形………………………………40
4-2-2 電腦模擬翹曲分析比較……………………………………………42
4-3實際射出量測分析翹曲變形………………………………………………43
4-3-1田口實驗計劃法-實際射出分析翹曲變形…………………………43
4-3-2 實際射出翹曲分析比較……………………………………………45
4-4 實際射出與電腦模擬翹曲分析比較………………………………………46
4-5壓力量測討論………………………………………………………………46
4-5-1 CAE模擬壓力量測……………………………………………………46
4-5-2 實際射出壓力量測…………………………………………………48
第五章 結論………………………………………………………………………100
5-1 翹曲測量研究……………………………………………………………100
5-2 模穴壓力量測研究………………………………………………………101
未來發展……………………………………………………………………………102
參考文獻……………………………………………………………………………103
著作………………………………………………………………………………106
附錄A……………………………………………………………………………107
附錄B……………………………………………………………………………125
自述…………………………………………………………………………………128

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