金屬注射成型隨形冷卻通道模具設計與製造

以作者查詢圖書館館藏

、以作者查詢臺灣博碩士

、以作者查詢全國書目

、勘誤回報

、線上人數：86

、訪客IP：3.22.248.247

姓名

高光明(Cao Sang) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

金屬注射成型隨形冷卻通道模具設計與製造
(CONFORMAL COOLING CHANNEL MOLD DESIGN AND MANUFACTURE FOR METAL INJECTION MOLDING)

相關論文

★ 光纖通訊主動元件之光收發模組由上而下CAD模型設計流程探討	★ 汽車鈑金焊接之夾治具精度分析與改善
★ 輪胎模具反型加工路徑規劃之整合研究	★ 自動化活塞扣環壓入設備之開發
★ 光學鏡片模具設計製造與射出成形最佳化研究	★ CAD模型基礎擠出物之實體網格自動化建構技術發展
★ 塑膠射出薄殼件之CAD模型凸起面特徵辨識與分模應用技術發展	★ 塑膠射出成型之薄殼件中肋與管設計可製造化分析與設計變更技術研究
★ 以二維影像重建三維彩色模型之色彩紋理貼圖技術與三維模型重建系統發展	★ 結合田口法與反應曲面法之光學鏡片射出成型製程參數最佳化分析
★ 薄殼零件薄殼本體之結構化實體網格自動建構技術發展	★ Boss特徵之結構化實體網格自動化建構技術發展
★ 應用於模流分析之薄殼元件CAD模型特徵辨識與分解技術發展	★ 實體網格建構對於塑膠光學元件模流分析之影響探討
★ 螺槳葉片逆向工程CAD模型重建與檢測	★ 電腦輔助紋理影像辨識與點資料視覺化研究

檔案

[Endnote RIS 格式]

[Bibtex 格式]

[相關文章]

[文章引用]

[完整記錄]

[館藏目錄]

[檢視]

[下載]

本電子論文使用權限為同意立即開放。
已達開放權限電子全文僅授權使用者為學術研究之目的，進行個人非營利性質之檢索、閱讀、列印。
請遵守中華民國著作權法之相關規定，切勿任意重製、散佈、改作、轉貼、播送，以免觸法。

摘要(中)

金屬注射成型（MIM）是一種結合了塑膠射出成型及粉末冶金技術優點的工藝技術，非常適合用於製造高強度、高精度和復雜幾何形狀的金屬零件。製造過程涵蓋了廣泛的技術，包括模具設計，粉末和黏合劑的混合、注塑、脫脂和後加工等。模具設計的成功將決定產品開發的成功與否，這將直接影響到MIM生產的效率及品質。然而，傳統的二維冷卻通道可能無法解決多穴模具溫度分佈不均勻的問題，並可能導致產品過熱及成型缺陷。在這項研究中，我們開發了一種用於 MIM 產品成型及製造的集成技術，包括用於模流分析的 MIM 模具開發技術、3D 隨形冷卻通道設計、金屬增材製造和 CNC 加工程序等。同時，通過實際的注塑試驗和分析，探討了該集成技術的可行性。最後，通過3D隨形模具冷卻系統的優化設計，可以提高MIM產品的冷卻效率和模具溫度的均勻性，這不僅成功地提高了產品的品質，並且也增加了成型程序的工作效率。

摘要(英)

Metal injection molding (MIM) is a process technology that combines the advantages of plastic injection molding and powder metallurgy technology, which is very suitable for manufacturing
metal parts with high strengh, high precision and complex geometry. The manufacturing process covers a wide range of technologies, including mold design, mixing of powder and binder, injection molding, degreasing, sintering and secondary processing in the post-process. The success of mold design will determine the success of products development, which will directly affects the efficiency and quality of MIM production. However, the conventional 2D cooling channels may not be effected with the problem of non-uniform temperature distribution for multi-cavity molds, and may cause over heated, shaping defects of the product. In this study, we develope an integrated technology for the MIM product shaping and manufacturing, including MIM mold development technology for mold flow analysis, 3D conformal cooling channel design, metal additive manufacturing and CNC processing. Also, through actual injection molding test and analysis the feasibility of this integrated technology is discussed. Finally, through the optimized design of the 3D conformal mold cooling system, the cooling efficiency of the MIM product and the uniformity of the mold temperature are improved, which not only successfully improves the product quality but also increase the working cycle of the molding process.

關鍵字(中)

★ 金屬注射成型
★ 隨形冷卻通道
★ 模流分析
★ 金屬增材製造

關鍵字(英)

★ Metal injection molding
★ conformal cooling channel
★ mold flow analysis
★ metal additive manufacturing

論文目次

CONTENTS
Abstract ..................................................................................................................................... i
Acknowledgements................................................................................................................. iii
List of Figures......................................................................................................................... vi
List of Tables............................................................................................................................ x
Chapter 1: Introduction.......................................................................................................... 1
1.1 Research Background ....................................................................................................... 1
1.2 Literature Review............................................................................................................... 5
1.3 Research Objective and Methodology ............................................................................ 13
1.3.1 Research Objective ...................................................................................... 13
1.3.2 Research Methodology .................................................................................17
1.4 Thesis Structure ............................................................................................................... 19
Chapter 2: Moldflow Analysis of MIM Link Parts.............................................................21
2.1 Introduction...................................................................................................................... 21
2.2 Conformal Cooling Channel for “Link” parts.................................................................. 21
2.2.1 The original 2D cooling channel mold .........................................................21
2.2.2 Design of 3D conformal cooling channel .....................................................24
2.2.3 Design of 3D conformal cooling channel including baffle...........................29
2.3 Mold flow analysis and results ........................................................................................ 36
2.3.1 Solid mesh construction................................................................................36
2.3.2 Material characteristics.................................................................................42
2.3.3 Parameter setting...........................................................................................48
2.4 Analysis and discussion of mold flow analysis results.................................................... 49
2.4.1 The influence of cooling channel type on the flow trend of cooling channel
...............................................................................................................................56
2.4.2 Comparison of cooling channel type to the time for the product to reach the
ejection temperature...............................................................................................61
2.4.3 The influence of cooling channel type on product temperature ...................66
2.4.4 The influence of cooling channel type on product warpage .........................66
v
2.4.5 The influence of cooling channel type on product powder concentration....71
2.5 Conclusion ....................................................................................................................... 73
Chapter 3: Mold Design and Manufacturing of MIM Link Parts.....................................75
3.1 Introduction...................................................................................................................... 75
3.2 Mold Design..................................................................................................................... 75
3.2.1 Choice of mold base......................................................................................75
3.2.2 Runner system design ...................................................................................76
3.2.3 Forming mold core design ............................................................................79
3.2.4 Conformal cooling channel mold core design ..............................................83
3.2.5 Ejection system design..................................................................................83
3.3 Conformal cooling channel mold core manufacturing .................................................... 86
3.4 Mold assembly ................................................................................................................. 90
Chapter 4: Mold Forming Test and Analysis Results of MIM “Link” Part.....................91
4.1 Introduction...................................................................................................................... 91
4.2 Experiment apparatus....................................................................................................... 91
4.2.1 Injection molding machine ...........................................................................91
4.2.2 Mold temperature controller.........................................................................95
4.3 Machine Identification experiment .................................................................................. 95
4.4 Short shot experiment ...................................................................................................... 99
4.4.1 Experiment planning.....................................................................................99
4.4.2 Experimental results and mold flow analysis verification..........................101
4.5 Checking mold temperature experiment........................................................................ 103
4.5.1 Experiment apparatus and objective ...........................................................103
4.5.2 Experiment result........................................................................................107
Chapter 5: Conclusion and Future Prospects....................................................................114
5.1 Conclusion .................................................................................................................... 114
5.2 Future Prospects............................................................................................................ 116
References............................................................................................................................. 118

參考文獻

References
[1] A. Dehghan-Manshadi, M. Bermingham, M. Dargusch, D. StJohn and M. Qian, “Metal
Injection Moulding of Titanium and Titanium Alloys: Challenges and Recent
Development”, Powder Technology, 2017
[2] S. C. Hu and K. S. Hwang, Powder Metallurgy, Vol. 43, 2000, pp. 239-244.
[3] M. Thornagel, “Simulating flow can help avoid mould mistakes,” Metal Powder Report,
Vol. 65, No. 3, 2010, pp. 26-29.
[4] M. Thornagel, “Injection moulding simulation: New developments offer rewards for the
PIM industry,” Powder Injection Moulding International, Vol.6, No. 1, 2012, pp. 65-68.
[5] Moldex3D: http://www.moldex3d.com/en/
[6] E. Sachs, E. Wylonis, S. Allen, M. Cima and H. Guo, “Production of injection molding
tooling with conformal cooling channels using the three dimensional printing process,”
Polymer Engineering and Science, Vol. 40, No. 5, 2000, pp. 1232-1247.
[7] C. Yan and A. Hsu, “Introduction of composite technology, combining machining with
selective laser melting for metal powder forming,” Molding Innovation, 2012, pp. 5-10.
[8] F. H. Hsu, K. Wang, C. T. Huang and R. Y. Chang, “Investigation on conformal cooling
system design in injection moulding,” Advances in Production Engineering &
Management, Vol. 8, No. 2, 2013, pp. 107-115.
[9] H. Qiao, “A systematic computer-aided approach to cooling system optimal design in
plastic injection molding,” International Journal of Mechanical Sciences, Vol. 48, No. 4,
2006, pp. 430-439.
[10] H.S. Park and X. P. Dang, “Optimization of conformal cooling channels with array of
baffles for plastic injection mold,” International Journal of Precision Engineering and
Manufacturing, Vol. 11, No. 6, 2010, pp. 879- 890.
[11] X. P. Dang and H. S. Park, “Design of U-shape milled groove conformal cooling channels
for plastic injection mold,” International Journal of Precision Engineering and
Manufacturing, Vol. 12, No. 1, 2011, pp. 73-84
[12] “Laser Additive Manufacturing: Going Mainstream,“
https://www.osaopn.org/home/articles/volumr_28/february_2017/features/laser_additive_
manufacturing_going_mainstream/
[13] Matsuura: https://www.matsuura.co.jp/
[14] eos: https://www.eos.info/en/additive-manufacturing/3d-printing-metal
[15] Sodick: https://www.sodick.co.jp/en/
[16] S. Mayer, “Optimized mould temperature control procedure using DMLS,” EOS
Whitepaper, 2009.
[17] Polyplastics: https://www.polyplastics.com/en/
[18] J. P. Beaumont, Runner and Gating Design Handbook: Tools for Successful Injection
Molding, Carl Hanser Verlag, Munich, 2004
[19] S. A. Jahan, T. Wu, Y. Zhang, J. Zhang, A. Tovar and H. Elmounayri, “Thermo-mechanical
design optimization of conformal cooling channels using design of experiments approach,”
Procedia Manufacturing, Volume 10, 2017, Pages 898-911.
[20] D. F. Heaney and C.D. Greene, 6 – “Molding of components in metal injection molding
(MIM),”
Editor(s): Donald F. Heaney, In Woodhead Publishing Series in Metals and Surface
Engineering, Handbook of Metal Injection Molding, Woodhead Publishing, 2012, Pages
109-133e.
[21] S. A. Jahan and H. El-Mounayri, “Optimal Conformal Cooling Channels in 3D Printed
Dies for Plastic Injection Molding,” Procedia Manufacturing, Volume 5, 2016, Pages 888-
900.
[22] S. A. Jahan and H. El-Mounayri, “A Thermomechanical Analysis of Conformal Cooling
Channels in 3D Printed Plastic Injection Molds,’ Applied Sciences, 2018
[23] Y. Chin and A. Hsu, Introduction of Composite Technology, Combining Machining with
Selective Laser Melting for Metal Powder Forming, moldex3d.com, 2012
[24] 周韋辰: <金屬粉末射出成型隨形水路模具設計製造與成型分析>, 國立中央大學碩
士論文, 2020

指導教授

賴景義(Jiing-Yih, Lai)

審核日期

2022-7-18

推文