智能化成型導引保壓模組建立與驗證

Development and Verification of Intelligent Molding Guidance Packing Module

10.6840/cycu201400964

吳建忠

射出成型 ； 智能化導引 ； 模流分析 ； 保壓 ； Cavity Pressure ； Packing Pressure ； Intelligent Molding Guidance ； CAE ； Injection molding

中原大學機械工程學系學位論文

2014年

碩士

陳夏宗

繁體中文

現今射出成型的參數調適多仰賴操作人員以經驗及詴誤法取得，雖可利用CAE模流分析軟體預測成型可能發生問題並提早對策因應，以往的經驗，模流分析與實際參數會有些差異，因為分析值無法直接設定於實際成型參數及生產中予以應用，來降低工時提升效率。本論文的目的是建立一套用實際值為理論基礎的參數模組，提供操作端輸入簡單資訊，即可獲得實際的成型參數，並探討熔膠於模穴內實際所受之壓力數值與成型條件參數下之關係。 本研究使用長帄板狀模型(Strip model)進行模流分析與射出成型實驗。模型建立使用了四種厚度0.5 mm、1 mm、1.5 mm、2 mm搭配不同流長比(L/t)，在模穴近澆口處，與充填末端處(約0.8 L)，設置壓力傳感器，量測其壓力差。而實驗與模擬的材料均採用光學級PMMA (CM211)，模溫設為40 oC，塑化溫度分別為240 oC、260 oC、280 oC。首先透過實驗取得充填數據而取得最佳充填時間，並在取得最佳充填時間後，以該最佳成型時間去進行二次充填，觀察保壓壓力在產品中的壓力變化歷程，並與模流軟體的分析結果進行比對，探討分析與實務上的差異性，來建立針對不同厚度、不同流長比的智慧型成型導引保壓壓力模組。最後以實際的驗證，建立標準模式後，所建立之保壓模組可用於智慧型控制器，同時依循相同模式可在建立產品收縮率以及冷卻相關模組。

Injection molding is a way to achieve mass production in nowadays. It possesses numerous advantages such as minimized cycle time and multi-cavities products in one shoot; however, containing complicated process conditions makes trouble in production operators always. Some may think that CAE(Computer-Aided Engineering) can be a good solution to assist them in production process. For CAE simulation technology, it is definitely a molding-solver but could take a long time for a well-trained software technician. Many researches are focus on the way to build a rule for attaining molding parameters rapidly but for packing stage. The purpose for this study is to design a rule of packing standard as a reference for molding industrial. The Study is using strip models to do the simulation and experiment. They are designed as four different thicknesses, and for each one included four flow length ratios. For every single model, there are two pressure sensors located on that, which are closed to the gate (0.1 of total length) and far away from the gate (0.8 of total length) and using material Chi Mei-CM211 (PMMA) with 40 oC mold temperature and three melted temperatures (240, 260, and 280 oC) for catching the flow data during filling stage. After finding out the minimizing pressure, it has been set as optimum filling time. Based on that, we design four packing pressures for each flow length and thickness and record the pressure datum. Those results are put together with simulation results for verifying the trend and accuracy. At the end of this study, a same methodology is conducted experiment in another injection machine for checking the feasibility. By this methodology, we hope that it could create a standard rule for packing stage and assist molding industrial for getting better in product quality and yield rate.

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