射出/壓縮成型加工參數對成品機械性質之最適化設計

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周宗億(JUNG-YI CHOU) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

射出/壓縮成型加工參數對成品機械性質之最適化設計

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摘要(中)

在複合材料產業中，樹脂轉注成型（Resin Transfer Molding, RTM）
是最常用來製造高強度、重量輕的強化塑膠之方法，但為了要降低射出壓力及縮短充填時間，便發展出一RTM的改良製程－射出/壓縮成型（Injection Compression Molding, I/CM）。
本實驗使用矩形鋁合金模具搭配一鋼製的外殼，使得模穴內為真空狀態進行實驗，並採用田口統計法探討射出/壓縮成型之加工參數（塑料注入壓力、模穴開啟間隙、塑料預熱溫度、模具閉合壓力、模具預熱溫度及膠化溫度）對於成品抗拉強度及彈性係數的影響。
由矩陣實驗結果加以分析，發現模具閉合壓力及塑料注入溫度的改變對成品性質影響最大，並且在研究當中取出一組最適參數A2B2C3D1E1F1。

摘要(英)

In the composite industry, Resin Transfer Molding (RTM) can produce high strength but light weight plastic products and is the most frequently used method. In order to reduce the injection pressure and filling time, improvement of RTM is made by the developing of Injection /Compression Molding (I/CM).
This experiment uses the aluminum alloy rectangle mould to match a steel outer cover, so that the mould cave during the experiments can be kept in the vacuum state. Taguchi Statistical Method is used to investigate the influence of the processing parameters (such as: resin injection pressure, mould opening gaps, resin preheat temperature, mould clamped pressure, mold preheated temperature and curing temperature) on the tensile strength and the elastic coefficient of the products.
Experimental results show that the mould clamped pressure and the resin preheated temperature are the most dominant factors for the product quality. An optimum group of parameters A2B2C3D1E1F1for I/CM process is also presented.

關鍵字(中)

★ 彈性係數
★ 抗拉強度
★ 射出/壓縮成型
★ 田口統計法

關鍵字(英)

★ Tensile Strength
★ Modulus of Elasticity
★ Taguchi Statistical Method
★ Injection/Compression Molding

論文目次

目錄
中文摘要.................................................Ⅰ
英文摘要.................................................Ⅱ
誌謝.....................................................Ⅲ
目錄.....................................................Ⅳ
表目錄.................................................. Ⅷ
圖目錄................................................. Ⅸ
符號說明...............................................XI
第一章緒論..............................................1
1-1 前言....................................1
1-2 文獻回顧..................................2
1-2-1 樹脂轉注成型（RTM）之研究文獻..........2
1-2-2 射出/壓縮成型（I/CM）之研究文獻.........5
1-3 研究目的..............................7
第二章實驗原理與設計方法..............................9
2-1 空孔度.................................9
2-2 滲透度......................................10
2-3 田口實驗設計法.............................11
2-3-1 可控因子的選擇 ..................11
2-3-2直交表的建構......................12
2-3-3標準直交表的選擇..............13
2-3-4因子效果之估計................13
2-3-5變異數法.....................14
2-3-6實驗資料之統計分析............15
第三章實驗設備與實驗步驟...............................16
3-1 實驗材料....................................16
3-1-1纖維蓆................................16
3-1-2樹脂與硬化劑..........................17
3-2 實驗設備....................................17
3-2-1微量電子天秤.........................17
3-2-2 樹脂加熱攪拌混合系統.................18
3-2-2-1 電動攪拌器...................18
3-2-2-2 真空幫浦.....................18
3-2-2-3 玻璃上下分離式反應瓶.........19
3-2-2-4 鐵氟龍攪拌棒及軸封...........19
3-2-2-5 溫度控制器與硬殼式電熱包.....19
3-2-3充填系統..............................20
3-2-3-1氮氣瓶........................20
3-2-3-2 壓力缸.......................20
3-2-4 膠化系統.............................21
3-2-5 模具和壓縮系統.......................21
3-2-5-1 模具.........................21
3-2-5-2 壓縮系統.....................23
3-3 實驗步驟....................................23
3-4 注意事項....................................25
第四章材料性質測試................................27
4-1 拉伸試驗（Tensile Test）之原理..................27
4-2 MTS拉伸性質量測.............................28
第五章實驗結果與討論...................................30
5-1 拉伸試驗....................................30
5-2 直交表矩陣實驗之結果與分析..................31
5-2-1 塑料注入壓力..........................32
5-2-2 模穴開啟間隙..........................33
5-2-3 樹脂預熱溫度..........................34
5-2-4 模具閉合壓力..........................34
5-2-5 模具預熱溫度..........................35
5-2-6 膠化溫度..............................35
5-3 最適因子水準的組合..........................36
5-4 真空度的影響................................38
5-5 模穴內未放滿纖維蓆..........................39
第六章結論.............................................40
參考文獻.................................................42
表目錄
表 2-1 可控因子及其水準配置表........................ 47
表2-2 標準直交表......................................48
表 2-3 L18 直交表及因子配置..............................49
表 3-1 樹脂LY 564 之性質................................50
表 3-2 硬化劑HY 2954之性質..............................50
表 3-3 Properties of LY564 / HY2954 Resin.................51
表 5-1 實驗資料彙總.....................................52
表 5-2 因子效果之總彙...................................53
表 5-3 抗拉強度之變異數（ANOVA）資料分析表................54
表 5-4 彈性係數之變異數（ANOVA）資料分析表................55
表 5-5 加法模式之預測...................................56
表 5-6 不同材料比抗拉強度之比較表.......................57
圖目錄
圖1-1a RTM製造流程.............................. 58
圖 1-1b I/CM製造流程............................... 58
圖 3-1 雙方向性玻璃纖維編紗束....................... 59
圖 3-2 樹脂加熱攪拌混合系統......................... 59
圖 3-3 溫度控制器................................. 60
圖 3-4 硬殼式電熱包................................... 60
圖 3-5 充填系統....................................... 61
圖 3-6 膠化系統（高溫爐）..... ......................... 61
圖 3-7 模具的實體......................................62
圖 3-8 上模具的幾何外型.............................. 62
圖 3-9 下模具的幾何外型.................................63
圖 3-10外殼的幾何外型................................. 63
圖 4-1 材料試驗機（Material Test System , MTS－810）........64
圖 4-2 複合材料拉伸試片............................... 64
圖 4-3a AC Controller................................. 65
圖 4-3b AC Controller 面板的Transducer Full Scale........65
圖 4-4 應變規（Extensometer）............................66
圖5-1 應力－應變圖................................... 67
圖 5-2 抗拉強度因子效果圖..............................68
圖 5-3 彈性係數因子效果圖...............................69
圖 5-4a 成品外觀................................... 70
圖 5-4b 有氣泡的成品.................................70

參考文獻

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指導教授

洪勵吾(Lih-Wu Hourng)

審核日期

2005-7-7

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