| 摘要: | 射出成型一直是產品量化最有利的生產方式之一，然而為了提高產品的機械強度、剛性、耐腐蝕、耐磨性等、同時又需要重量輕等需求，很多時候會改用玻璃纖維強化塑膠(FRP, Fiber-reinforced plastic)來達到要求，也就是本研究要被測試的材料尼龍+50%玻璃纖維(PA66+50%GF)。
為了使玻璃纖維強化塑膠在射出後達到尺寸精度、幾何公差、表面粗糙度、組裝需求等，一般都需要使用電腦數值控制工具機(Computer Numerical Control，CNC)進行二次加工來達到要求。
但由於材料本身的不連續性、不均勻性、纖維容易碎化等，會使刀具在加工時極具磨蝕性，使刀具耗損量增大，影響生產量化的穩定，進而增加製造成本，因此，選擇適合的刀具及鍍層是加工廠非常重要的課題。
本研究使用KYOCERA的刀片及物理氣相沉積(Physical Vapor Deposition，PVD)蒸鍍方式將四種鍍層鍍在刀片上，分別為: 類金剛石(DLC)、氮化高鋁鈦(AlTiN)、氮化鋁鈦矽(AlTiSiN)、氮化鋁鈦鋯矽(AlTiZrSiN)，並用三組加工參數對PA66+50%GF的射出成型產品進行車削，並記錄刀腹磨耗(Flank wear)，找出適合加工PA66+50%GF的刀具鍍層。
結果顯示DLC鍍層因為摩擦係數低、表面較光滑，在三組實驗數據，都顯示有較長的切削長度和切削時間，即使Vc值提高，仍保有較長的刀具壽命，因此，若以刀具壽命來看，會比較推薦DLC鍍層，但DLC鍍層費用較高，需評估在成本管控上，是否仍保有競爭優勢。
;Injection molding has always been one of the most favorable production methods for product quantification. However, in order to improve the mechanical strength, rigidity, corrosion resistance, wear resistance, etc. of products, and at the same time need to be light in weight, glass fiber reinforced plastics are often used instead. FRP, Fiber-reinforced plastic) to meet the requirements, that is, the material to be tested in this study is nylon + 50% glass fiber (PA66 + 50% GF).
In order to make the glass fiber reinforced plastic meet the dimensional accuracy, geometric tolerance, surface roughness, assembly requirements, etc. after injection, it is generally necessary to use Computer Numerical Control (CNC) for secondary processing to meet the requirements.
However, due to the discontinuity and inhomogeneity of the material itself, the fibers are easily fragmented, etc., the tool will be extremely abrasive during processing, which will increase the tool wear, affect the stability of production quantification, and increase the manufacturing cost. Therefore, Choosing the right tool and coating is a very important issue for the processing plant.
In this study, KYOCERA′s blade and Physical Vapor Deposition (PVD) evaporation method were used to coat four kinds of coatings on the blade, namely: diamond-like carbon (DLC), high-aluminum titanium nitride (AlTiN), nitrided Aluminum-titanium-silicon (AlTiSiN), aluminum-titanium-zirconium-silicon nitride (AlTiZrSiN), and three sets of processing parameters are used to turn PA66+50%GF injection molded products, and record the flank wear to find out the suitable processing PA66 +50% GF tool coating.
The results show that the DLC coating has a long cutting length and cutting time in the three sets of experimental data because of its low friction coefficient and smooth surface. Even if the Vc value is increased, it still maintains a long tool life.
Therefore, if the tool life is From the point of view, DLC coating will be recommended, but the cost of DLC coating is relatively high, and it is necessary to pay attention to whether it can still maintain a competitive advantage in total cost control. |
