博碩士論文 107353001 詳細資訊




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姓名 劉金泓(Jin-Hong Liu)  查詢紙本館藏   畢業系所 機械工程學系在職專班
論文名稱 結合模流分析與實驗設計實現穩健射出成型與理想成型視窗的預測
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摘要(中) 本研究欲透過Moldex3D進行模流分析,並藉由解析所得到的分析結果,了解產品成型參數的調整對於產品狀態的各種影響,例如是否會造成產品的短射、縮水、過度飽壓或翹曲等不良狀態的發生。本研究也將依循理想充填時間與理想保壓時間的預測及定義,作為本實驗參數的基礎參數,研究最後所得的成型視窗及理想成型參數資料,可作為研究人員調機時的成形參數參考依據。期許藉由此研究方案改善工廠如面臨設備不足,或無人力支援可安排射出成形實驗驗證時的困難,又或者是新材料不易取,致使得存量不足以提供批量性驗證的狀態下,仍可實現工廠於實際量產前,協助定義出較為理想及穩健的成型參數。
本研究因為考量成型參數有數個控制因子,但為了以最少的分析次數,獲取適當的分析結果,本研究將透過田口實驗設計法,以實驗穩健的射出成型實驗程序,建立較為有效率的實驗方法。文中也將探討各研究因子的顯著性差異,作為工程成員決定調機參數優先順序的參考依據。本研究將選定產品翹曲變形量的變化,作為本研究的實驗組與對照組,作為模流分析正確性的判定依據。最後進一步藉由模流分析理論最佳化的模擬結果,可給予機台操作人員合理的射出成形預測趨勢,協助定義該機台最為合適的生產參數,來實現產品量化且品質一致的理念。
摘要(英) In order to rapidly research a suitable set of injection parameters for predicting the robust injection process, In this study, we use a software of Moldex3D to parse results by evaluation of simulation data, the injection speed and the gate seal time can be stablished and estimated. Robust design is an effective way to improve the quality of products in the filed of injection molding , we can control these noise factors to force variability to occur the results what we want. By identifying optimal control factor settings that make the process or product robust and predict the range of the molding window .Through this study , with a view to improving the problem of limited resource and it can make full use of resources and avoid unnecessary waste in factory.
Considering the points for several process parameters as most important, and we are all looking to optimize results while minimizing time and resources in the factor. The objective of this study is using the procedure adopted in using Taguchi Method to deal with optimization problems in which a certain measure of robustness. In this study, we will not only explain a comparison between numerical simulation and experimental results, but also evaluate the usability of the process parameters optimization of the numerical simulation. The result shows that the injection speed and the gate seal time can be stablished and estimated by these two ways. The section of predicting the range of the molding window that shows the analysis results could be used for our operator to judge and check the process parameter prediction.
關鍵字(中) ★ 成型視窗
★ 穩健成型
★ 射出成型
★ 縮水
關鍵字(英) ★ Process (Molding) Window
★ Robust decision
★ Injection Molding
★ Sink mark
論文目次 摘要 I
ABSTRACT II
致謝 III
CONTENT IV
圖目錄 VI
表目錄 VIII
一、緒論 1
1.1 成型參數–Process parameters 1
1.2 產品異常判定–Judging criterion the failure rule 2
1.3 成型視窗簡介–(Process window 或稱 Molding window) 3
二、 模流分析研究目的與方式 4
2.1 模流分析研究資料 4
2.2 最佳充填時間及最佳保壓時間模擬分析研究過程 5
2.3 模流分析研究與實驗設計–Design of experiment (DOE) 8
2.4 直交表與模擬結果彙整–The layout and results 12
2.5 模擬理想成型視窗–Molding window 14
2.6 熔膠波前的歷程–Melt front time 15
2.7 凹痕指標分析–Sink Mark Indicator 16
2.8 Z方向的翹曲分析–Warpage Z-displacement [mm] 16
2.9 結合線分析–Welding line result 17
2.10 冷卻結果的判定–Cooling result 18
2.11 模穴內的溫度與壓力變化–Temperature distribution 19
三、 實驗研究目的與方式 21
3.1 實驗研究方法 21
3.2 最佳充填時間及最佳保壓時間的實驗研究分析過程 21
3.3 實驗研究理想成型視窗–Molding window 23
3.4 分析對比實驗之理想成型視窗–Molding window 24
3.5 產品翹曲變形量分析–Warpage measurement 25
四、製程參數優化 OPTIMIZATION OF THE PROCESS PARAMETERS 28
4.1 模流分析研究與實驗設計結果–Design of experiment (DOE) Results 28
4.2 考量模具溫度的實驗設計結果–Considering the tooling temperature 35
五、結論 43
六、參考文獻 44
七、附錄 46
參考文獻 1. Maw-Ling Wang, Rong-Yeu Chang, Chia-Hsiang (David) Hs(201806), Molding Simulation Theory and Practice, Hanser Publications , P 92~117.
2. HUAMIN ZHOU(201302) COMPUTER MODELING FOR INJECTION MOLDING (Simulation, Optimization, and Contro) , John Wiley & Sons Inc , P 7~8.
3. Suhas Kulkarni(201008), Robust process development and scientific Molding (Theory and Practice), Hanser Publications, P 110~224.
4. Huang Gao, Yun Zhang, Yang Fu, Ting Mao, Huamin Zhou and Dequn Li(2017), Process parameters optimization using a novel classification model for plastic injection molding, The International Journal of Advanced Manufacturing Technology, 94, 1-4, (357-370)
5. Shengrui Yu, Yun Zhang, Ding Yang, Huamin Zhou, Juncong Li(2014), Offline Prediction of Process Windows for Robust Injection Molding, Journal of Applied Polymer Science, 131(18) .
6. Chao-Tsai Huang*, Yi-Hsuan Hsu, Bo-Syuan Chen (2019), Investigation on the internal mechanism of the deviation between numerical simulation and experiments in injection molding product development . Polymer Testing. Volume 75 : Pages 327-336
7. Azad, R.; Shahrajabian, H. (2018), Experimental Study of Warpage and Shrinkage in Injection Molding of HDPE/rPET/Wood Composites with Multiobjective Optimization. Mater. Manuf. Processes. 34, 274–282. DOI: 10.1080/10426914.2018.1512123.
8. Wen-Chin Chen & Denni Kurniawan (2014) ,Process parameters optimization for multiple quality characteristics in plastic injection molding using Taguchi method, BPNN, GA, and hybrid PSO-GA. International Journal of Precision Engineering and Manufacturing 15:1583–1593.
9. Xiaoxin Wang , Guoqun Zhao , Guilong Wang(2013), Research on the reduction of sink mark and warpage of the molded part in rapid heat cycle molding process , Materials and Design , 47:779–792.
10. Xianjun Sun, Patricia Tibbenham, Danielle Zeng, Xuming Su, Shiyao Huang & Hong-tae Kang(2019),Procedure development for predicting the sink mark of injection molded thermoplastics by finite element method . The International Journal of Advanced Manufacturing Technology ,103 : (4095-4107)
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12. Kurt M, Kaynak Y, Kamber OS, Mutlu B, Bakir B, Koklu U (2009), Influence of molding conditions on the shrinkage and roundness of injection molded parts. Int J Adv Manuf Technol 46:571–578.
13. Carlos Vargas 1, Juan Sierra 2, Juan Posada 2, Juan F. Botero-Cadavid(2017), Analysis and modeling of simulated residual stress of mold injected plastic parts by using obust correlations, REVISTA MATERIA, 22 e-11894 UNSP
14. Kuo-Ming Tsai & Hao-Jhih Luo(2014), CoMParison of injection molding process windows for plastic lens established by artificial neural network and response surface methodology. The International Journal of Advanced Manufacturing Technology 77:1599–1611.
15. Kuo-Ming Tsai & Bin-Hong Tang(2014) ,Determination of injection molding process window based on form accuracy of lens using response surface methodology. The International Journal of Advanced Manufacturing Technology 75:947–958.
指導教授 傅尹坤(Yiin-Kuen Fuh) 審核日期 2020-7-8
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