傳統以2D水路為主的金屬射出成型(MIM)模具無法貼近模仁核心，因此對於模仁之冷卻不均勻，導致於製程參數調整範圍窄，模具試模與修模時間長。由於金屬積層製造技術之成熟，以異型水路模具設計取代傳統2D水路，並以結合金屬積層製造與CNC加工之方式製造模仁，可克服傳統CNC設備無法加工3D水路的問題。本計畫的目的為發展一整合模流分析、異型水路設計、金屬積層製造和CNC加工之MIM模具開發技術，並應用於一鎖類零件之MIM成型，以縮短成型週期，並增加生產效率。本計畫之研究方法為:(1)MIM零件異型水路模具設計:開發一模四穴之鎖類零件異型水路模具，建構完整模具CAD模型，並著重異型水路之設計；(2)異型與2D水路模具之模流分析與比較:利用模流分析進行模具與水路散熱情形分析，比較異型與2D水路之差異，並優化異型水路結構；(3)異型水路模仁金屬積層製造與模具加工:以金屬積層製造列印模仁雛型，再以CNC加工進行模仁二次加工及模座加工，最後完成整座模具；與(4)異型水路模具測試及與2D水路模具相關資料比較:進行異型水路模具測試與修模，其成品和成型特性與2D水路模具之相關資料進行比較。藉由此一計畫之實施，可引進模流分析技術予合作廠商，並且提升其開發MIM異型水路模具的技術。 ;Two-dimensional (2D) cooling channels are commonly used in the mold design of metal injection molding (MIM). The temperature distribution near the core and cavity of an injection mold is often not uniform because such parallel cooling channels cannot be distributed uniformly; it often results in narrow range in process parameters that can be adjusted and lengthy time required in mold testing modification. Conformal cooling has recently been used to replace 2D cooling because of the mature of metal additive manufacturing technology; this technology can be used to manufacture three-dimensional (3D) cooling channels embedded inside the core and cavity of a mold, which is impossible using CNC machining. The purpose of this project is to develop an MIM mold developing technology by integrating mold flow analysis, conformal cooling design, metal additive manufacturing, and CNC machining. An injection mold with four cores and conformal cooling channels for a lock part is developed to reduce the injection cycle and increase the productivity of such parts. The method proposed in this study includes: (1) mold design for the MIM part: develop a mold with four cores and conformal cooling channels for the lock part. Also, construct all CAD models of such a mold, emphasizing the design of conformal cooling channels; (2) mold flow analysis of the MIM part: apply mold flow analysis to analyze the cooling process of the proposed mold design. Also, compare the difference between the proposed conformal-cooling and 2D cooling. Also, optimize the position and shape of the proposed conformal cooling channels; (3) mold manufacturing: apply metal additive manufacturing to print the initial shape of the core and cavity first. Then, apply CNC machining to machine the final shape of the core and cavity. Also, manufacture the mold base and assemble the entire mold; and (4) mold testing and modification: perform mold testing and modification for the proposed mold. Also, compare the final product and the injection property of the proposed mold with those of 2D cooling mold. By the implementation of this project, we can introduce the mold flow analysis technology to the company, and increase its technology for developing MIM molds with conformal cooling channels.
