超高分子量聚乙烯之機械性質與微結構成型性研究

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姓名

郭献彰(Hsien-Chang Kuo) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

超高分子量聚乙烯之機械性質與微結構成型性研究
(Study on mechanical properties and microstructure of ultra-high molecular weight polyethylene)

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摘要(中)

本文主要是使用射出成型與射出壓縮成型製程探討超高分子量聚乙烯(Ultra High Molecular Weight Polyethylene，UHMWPE)的充填性質、成型參數條件、機械性質、磨耗特性與微結構成型性。其主要研究結果如下：
無縫合線與有縫合線的拉伸試片實驗結果顯示，在成型無縫合線試片時，試片拉伸段與入膠口的橫截面尺寸大小及形狀對抗拉強度有較明顯的影響，相較之下不同的射出製程參數對抗拉強度的影響則是較小；此外，縫合線的產生降低了射出製程參數及橫截面尺寸對試片抗拉強度的影響，且在充填試片厚度較厚的有縫合線拉伸試片時，縫合線兩側有較好的分子鍵結能力；縫合線區域的主要表面缺陷為微孔洞、微裂縫和不完整的分子鍵結組織。在Ball-on-Plane的配對與乾摩擦條件下，不同的射出成型製程參數與磨耗參數會影響UHMWPE摩擦係數值的變化，摩擦係數有隨著接觸負荷與滑動頻率的增加而增加的趨勢，磨耗體積損失則呈現不規則的增減，大致上在較高的射出成型參數設定下有最低的磨耗體積損失；UHMWPE主要的表面磨耗機構為塑性變形、微溝槽(Microgroove)與波浪狀(Wavelike)組織。射出成型微結構時，射出速度對於微結構的高度變化有顯著的影響，且在射出成型尺寸200 μm以下的微結構時，成型品上的微結構外觀容易於脫模過程中發生變形以及在微結構周圍產生拉扯的痕跡；而在射出壓縮成型微結構時，由於射出壓縮成型過程中給予足夠的固定壓縮力(30 tonf)，因此射出壓縮成型製程參數對於微結構高度的變化則較無顯著之影響，但可獲得較為穩定的微結構高度與良好的表面外觀。

摘要(英)

The wear behavior, mechanical properties and microstructure of injection molded ultra high molecular weight polyethylene (UHMWPE) parts has been studied. As far as tensile strength is concerned, the influences of process conditions and cross-sectional dimensions on the tensile strength of a weld line are investigated. In addition, the weld line characteristics of structures and different cross-sections are explored in this study as well. Five specimens, with different cross-sections, are injection molded simultaneously. With the Taguchi method, three process variables including melt temperature, mold temperature, and injection velocity were found to be the most significant. Furthermore, in order to understand more about the effect of the process parameter, the single-factor experiments are used. Experimental results show that the parametric influence is relatively little on the cross-sectional dimensions. The results also show that the tensile strength and surface hardness are affected at injection molding conditions and sliding contact loads. As far as wear behavior is concerned, experimental results show that the different wear contact loads and varied injection molding conditions have an influence for friction coefficient and wear volume loss of UHMWPE specimens. The higher sliding contact load results in a lower friction coefficient. Moreover, lower wear volume loss is often occurred in the specimen molded with the highest injection molding level. The morphologies of the worn surfaces and the cross-section of specimens were examined with optical microscope and scanning electron microscope, respectively. Plastic deformation, grooves and wavelike formation are the main wear mechanism on the surface in wear tests of UHMWPE. As far as microfabrication is concerned, replication accuracy was investigated for microinjection molding and microinjection compression molding. The mold insert was fabricated by stainless steel metal etching method. The mold insert includes rectangular groove of 100 μm, circular groove array of 100–300 μm and square groove array of 100–300 μm. Both the microinjection molded part and the microinjection compression molded part were observed under microscope to compare the replication accuracy. To measure the microstructure profile, a high performance surface profiler was used. Among mold insert, microinjection molded parts and microinjection compression molded parts were measured. The experiment results show that the UHMWPE can be filled in microcavities by microinjection molding and microinjection compression molding technology. The height and shape of microstructure were influenced by injection molding process parameters. For an injection molded part, injection velocity was the most influential factor. The height and shape of microstructure shows that microinjection compression molding was a more stable process than microinjection molding, due to it can provide an enough compression force.

關鍵字(中)

★ 微結構
★ 射出成型
★ 磨耗機構
★ 縫合線
★ 超高分子量聚乙烯
★ 摩擦係數
★ 抗拉強度
★ 射出壓縮成型

關鍵字(英)

★ Microinjection Molding
★ Tribological Properties
★ Weld Line
★ Tensile Strength
★ UHMWPE
★ Microinjection Compression Molding

論文目次

摘要 i
Abstract ii
誌謝 iv
目錄 v
圖目錄 ix
表目錄 xiv
符號說明 xv
第一章緒論 1
1-1研究背景 1
1-2文獻回顧 2
1-2-1 UHMWPE相關文獻 2
1-2-2縫合線相關文獻 5
1-2-3微結構相關文獻 7
1-3研究動機與目的 8
1-4論文架構 9
第二章理論基礎 13
2-1射出成型製程 13
2-2射出壓縮成型製程 14
2-3拉伸試驗 16
2-4縫合線 17
2-4-1影響縫合線強度的因素 18
2-4-2縫合線鍵結度 18
2-5維克氏硬度測試 20
2-6田口實驗方法 20
2-7磨潤理論 23
2-7-1摩擦 23
2-7-2磨耗 24
第三章實驗方法與步驟 35
3-1實驗材料 35
3-2射出成型機與模溫機 36
3-3實驗模具和模仁的製作方法 36
3-3-1拉伸試片與磨耗試片模具 37
3-3-2微結構模具 37
3-3-3金屬蝕刻模仁 38
3-4試驗設備與方法 39
3-4-1拉伸試驗機 39
3-4-2摩擦與磨耗試驗機 40
3-4-3硬度試驗機 41
3-4-4表面輪廓儀 41
3-5實驗方法 41
3-6成品的量測方法與步驟 42
3-6-1拉伸試片的量測 42
3-6-2磨耗試片的量測 43
3-6-3微結構成品的量測 44
第四章研究結果與討論 55
4-1拉伸試驗 55
4-1-1田口實驗分析 56
4-1-2無縫合線的拉伸單變數實驗分析 57
4-1-3有縫合線的拉伸單變數實驗分析 59
4-1-4無縫合線與有縫合線拉伸試片破斷面觀察 59
4-1-5縫合線表面觀察 60
4-1-6小結 61
4-2射出成型製程參數對摩擦與磨耗之影響 61
4-2-1摩擦行為 62
4-2-2磨耗行為 63
4-2-3磨耗機構 65
4-2-4拉伸強度和磨耗體積損失的影響 66
4-2-5硬度試驗 66
4-2-6小結 67
4-3磨耗參數對摩擦與磨耗之影響 68
4-3-1摩擦行為 68
4-3-2磨耗行為 70
4-3-3磨耗機構 71
4-3-4硬度試驗 72
4-3-5小結 72
4-4微結構成型實驗 73
4-4-1射出成型製程參數對微結構高度之影響 74
4-4-2射出壓縮成型參數對微結構高度之影響 75
4-4-3射出成型與射出壓縮成型之微結構成型性比較 76
4-4-4小結 77
第五章結論與建議 128
5-1結論 128
5-2建議 129
參考文獻 131
個人簡歷 138

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指導教授

鄭銘章(Ming-Chang Jeng)

審核日期

2010-7-20

推文