熔膠翻轉技術改善多模穴充填不平衡之研究

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姓名

陳光佑(Guang-You Chen) 查詢紙本館藏

畢業系所

光機電工程研究所

論文名稱

熔膠翻轉技術改善多模穴充填不平衡之研究
(Investigation of melt rotation technology to improve multi-cavity filling imbalance)

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摘要(中)

在模流分析中，網格種類的選擇直接影響模擬分析的精確度與計算效率，本研究以自動化生成邊界層網格(Boundary layer mesh, BLM)與需手動搭建六面體網格(Hexahedron)以Moldex3D R17軟體模擬八穴模具的充填過程，結果得知，BLM網格數較多，分析時間長且效果不佳，而Hexa網格數較少，分析時間較短，能模擬出多模穴充填不平衡現象。
為了改善充填不平衡現象，使用添加限流器(Restrictor)或熔膠翻轉技術MeltFlipper®，並利用充填不平衡係數(Filling imbalance coefficient, )，用來量化充填不平衡，結果得知，在次流道添加限流器的改善效果不足，應不適用於此模具，而在主流道與次流道之間使用MeltFlipper®技術可改變熔膠中的不對稱條件，改善充填不平衡，提高產品質量。
使用反應曲面法對流道翻轉區域進行優化，經由迴歸分析，在充填過程中，翻轉區域高度為顯著因子，優化後流道與原始流道之充填不平衡改善78%。

摘要(英)

In the molding simulation analysis, mesh type directly affects the accuracy and calculation efficiency of simulation. In this study, auto-generated boundary layer mesh (BLM) and manual constructed hexahedral mesh (Hexa) are used to simulate the filling process of an eight-cavity mold by using Moldex3D R17 software. Compared to Hexa, BLM has larger amount of mesh which carries out the problem of inefficiency simulation. However, Hexa has better efficiency and better resolution on the phenomenon of filling imbalance in multi-cavity molds.
In this study, restrictor and MeltFlipper® technologies are used to improve the imbalance of filling through the coefficient of filling imbalance . According to the results of simulation, the improvement of restrictor in secondary runner is insufficient and unsuitable for this mold. However, the MeltFlipper® technology used between primary and secondary runners alters the asymmetric melt situations, and improve the quality of the product.
By using the response surface methodology, we discuss the optimal dimension of flip region. The height of the flip region is determined as a significant factor through regression analysis during filling process, thus improving the filling imbalance by 78%.

關鍵字(中)

★ Moldex3D
★ 限流器
★ 熔膠翻轉MeltFlipper®
★ 反應曲面法

關鍵字(英)

★ Moldex3D
★ restrictor
★ MeltFlipper® technology
★ response surface methodology

論文目次

摘要 i
Abstract ii
致謝 iii
目錄 iv
圖目錄 viii
表目錄 xii
第1章、緒論 1
1-1 前言 1
1-2 文獻回顧 2
1-2-1 充填不平衡相關文獻 2
1-2-2 改善充填不平衡方法相關文獻 4
1-2-3 實驗設計法相關文獻 5
1-3 研究目的與方法 6
第2章、基本原理與理論模式 8
2-1 充填效應 8
2-2 充填不平衡 10
2-2-1 流道布局形成充填不平衡 10
2-2-2 流道中剪切引起充填不平衡 11
2-3 改善充填不平衡方法 12
2-3-1 限流器 13
2-3-2 熔膠翻轉技術MeltFlipper® 14
2-3-3 熔膠翻轉技術MeltFlipper MAX™ 15
2-3-4 模內可調流變控制iMARC™ 17
2-4 網格性質 19
2-5 反應曲面法 23
2-5-1 中央合成設計與Box-Behnken設計 23
2-5-2 迴歸分析 26
第3章、研究方法 30
3-1 鏡筒模型 30
3-2 材料 31
3-2-1 黏度曲線 31
3-2-2 PvT曲線 32
3-3 網格建構 33
3-3-1 流道網格生成 33
3-3-2 鏡筒網格生成 35
3-3-3 水路與模座 36
3-4 模流分析 37
3-4-1 成型參數 37
3-4-2 充填不平衡係數 39
3-5 改善充填不平衡方法 40
3-5-1 限流器應用 41
3-5-2 熔膠翻轉應用 41
3-6 統計分析 42
3-6-1 決定品質特性與理想機能 42
3-6-2 選定實驗因子與水準 43
3-6-3 反應曲面之中央合成法 43
3-7 流率快慢設定 44
第4章、結果與討論 47
4-1 BLM網格與混搭式(HEXA+BLM)網格種類比較結果 47
4-1-1 全BLM與混搭式網格品質 47
4-1-2 溫度分布結果 48
4-2 改善充填不平衡結果 50
4-2-1 限流器結果 50
4-2-2 流道翻轉結果 51
4-3 實際短射照比對結果 53
4-4 中央合成設計結果 55
4-4-1 中央合成組別 55
4-4-2 迴歸分析 56
4-4-3 優化結果 59
4-5 流率快慢影響流動結果 61
4-5-1 進澆口壓力與充填流率圖 61
4-5-2 溫度分布與剪切 63
第5章、結論與未來展望 66
5-1 結論 66
5-2 未來展望 67
參考文獻 69

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指導教授

鍾禎元(Chen-Yuan Chung)

審核日期

2021-7-19

推文