臺灣博碩士論文加值系統

塑膠射出成型一直是各產業產品中不可或缺的製程技術，為了縮短產品的組立成本及時間，金屬嵌入式 (Insert Mold) 的塑膠射出成型製程也紛紛被業界應用，由於其製程參數繁多，為減少產品生產週期與試模時間以降低成本，因此可藉由電腦輔助工程模流分析技術，利用電腦快速計算功能，模擬射出成型的過程，以作為成型前的設計或是成型後問題的解決。

目前模流分析多針對傳統射出成型的模擬，只考慮其冷卻管路排列方式與不同的製程參數對產品的影響，然而並未探討金屬嵌入式 (Insert Mold) 的塑膠射出成型之模擬與實際製程參數之差異性及可行性。本研究利用Moldflow模流分析軟體，針對金屬嵌入式 (Insert Mold) 塑膠射出成型的製程參數進行模擬，並以實際案例探討模擬與實際製程參數之差異性及模擬可靠度，經模流分析結果除了熔膠溫度與實際射出的熔膠溫度差異較大之外，其餘條件也與實際射出成型條件相近，而利用ANSYS在嵌入件的變形分析結果也確認了模具中的頂針位置及數量足以固定嵌入件而不產生變形。因而期望藉本文之分析結果以提供業界在進行相關模擬時的參考依據。

Plastic injection molding is a popular manufacturing technology of plastics in various industries. In order to shorten assembly time and cost, the plastic injection technology of insert molding have been applied extensively. The CAE mold flow technology has been adopted to simulate the injection process in order to reduce the manufacturing cycle and the cost of trial-and-error. It can also resolve forming problems and improve mold design before production.

Current CAE mold flow simulations focus only on the cooling system and the effects of process parameters on product quality. It has not put under consideration of the inserted metal parts. In this study, the commercial Moldflow analysis software was employed to perform process simulation of insert molding. The results were compared with the actual processed components. It is found that the results were very comparable except for the process parameter of melt temperature. The effects of the dragging force of the melt flow on the inserted part were analyzed by the ANSYS and were found having minimal effects on the deformation of the inserted part. The feasibly of simulation of insert molding was provened from this case study. And the results show quite promising for industrial applications.

書名頁 …………………………………………………………………… I
論文口試委員審定書 …………………………………………………… II
授權書 …………………………………………………………………… III
中文摘要 ………………………………………………………………… IV
英文摘要 ………………………………………………………………… V
誌謝 ……………………………………………………………………… VI
目錄 ……………………………………………………………………… VII
表目錄 ………………………………………………………………… VIII
圖目錄 …………………………………………………………………… IX
一、 緒論 ………………………………………………………………… 1
1.1 前言 …………………………………………………………… 1
1.2 文獻回顧 ……………………………………………………… 2
1.3 研究動機 ……………………………………………………… 3
1.4 本文架構 ……………………………………………………… 3
二、 嵌入式塑膠射出成型理論…………………………………………… 5
2.1 射出成型原理 ……………………………………………………… 5
2.2 嵌入式射出成型簡介 ……………………………………………… 7
2.3 嵌入式模具之基本結構 …………………………………………… 9
2.4 流道系統設計 ………………………………………………………12
2.5 進澆口設計 …………………………………………………………14
2.6 冷卻系統之設計 ……………………………………………………16
三、 模型建構與模擬分析 ………………………………………………18
3.1 MoldFlow軟體簡介…………………………………………………18
3.2 嵌入成型與傳統模流分析之比較 …………………………………18
3.3 實例探討 ……………………………………………………………20
3.4 模擬步驟 ……………………………………………………………23
3.5 實體模型建構 ………………………………………………………25
3.6 塑料性質決定 ………………………………………………………29
3.7 成型條件設定 ………………………………………………………30
四、 模擬結果分析 ………………………………………………………33
4.1 模擬之成型條件與實際射出條件之比較 …………………………35
4.2 嵌入件之變形分析 …………………………………………………41
4.3 模擬與實際射出成型之差異原因分析 ……………………………45
4.4 CAE軟體應用之效益分析……………………………………………48
五、 結論與未來展望 ……………………………………………………50
5.1 結論 …………………………………………………………………50
5.1 未來展望 ……………………………………………………………50
參考文獻 ……………………………………………………………………52

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