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研究生: 陳福添
Chen, Fu-Tien
論文名稱: 以蒸汽加熱可變溫模具系統開發
Development of a Steam Based Variotherm Molding System
指導教授: 黃聖杰
Hwang, Sheng-Jye
學位類別: 碩士
Master
系所名稱: 工學院 - 機械工程學系碩士在職專班
Department of Mechanical Engineering (on the job class)
論文出版年: 2008
畢業學年度: 96
語文別: 中文
論文頁數: 76
中文關鍵詞: 模具快速加熱可變溫
外文關鍵詞: rapid heating, variotherm, mold
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  • 射出成型過程,保持模具於高溫狀態雖有助於成型,但相對的成型週期也會增加。提高射出品質與減少傳統射出常見的問題並降低成型週期,為本文研究重點。本研究即為以蒸汽加熱可變溫模具,提高射出零件的良率,增加生產效能,並進一步減少成形週期。
    首先構思模具設計部分,想要快速加熱模具必需將加熱流道越靠近模穴越好,流道設計部分還需考慮溫度分布的均勻,故流道的設計採用螺旋曲線設計,使模穴的溫度能達到平均的分佈,進而各種射出成品的形狀都能適用在這設計基礎上。根據上述的設計,模具部分需考慮模穴底部的強度,避免模穴因為射出壓力過大時而產生變形,因而使用ANSYS軟體分析模穴的變形量,確認是否會因變形嚴重造成加熱蒸汽外洩,危及工作人員的安全。
    再用ANSYS軟體分析,高溫蒸汽在模具內,短時間加熱流道時的反應,確認模仁表面溫度分布情形與實驗數值是否達到預期之表面溫度。但因鍋爐設備容量不足,無法達到預期,遂藉由各項參數進行田口方法分析計算出哪些參數是重要因子。再藉由田口方法的望大特性進行進一步的ANSYS電腦模擬,驗證其模仁表面的加熱速度並確認設計之可行性。結果發現,若要能夠快速加熱模具需要非常大的鍋爐,對要經濟化生產射出件所要付出的成本相當的高。

    In injection process, holding high mold temperature will increase injection quality and reduce traditional injection defects. However, the comparative molding cycle time will increase as well. Our research was to develop a steam based variotherm system in order to increase injection part quality and reduce the molding cycle time.
    First, to increase the heating efficiency of the variotherm heating system, the heating channel should be placed as close to the mold cavity surface as possible. It should also consider about even temperature distribution in the channel design. Therefore, the design of heating and cooling channel was set to be spiral shaped. After considering the heating efficiency, engineers need to think whether the strength of the mold cavity is high enough to sustain the excessive amount of injection pressure during molding. Consequently, ANSYS software was adopted to analyze the strength of mold cavity.
    Next, in order to make sure whether mold can be heated to the expected temperature during a short period of time, ANSYS software was used to analyze and predict the temperature distribution of mold heated after a short period of time. The result showed that the heater cannot reach the temperature. Because the boiler capacity was not enough, use Taguchi Method to analyze, and find the important factor influencing the heating rate. Use large-the-better factor in ANSYS analysis, then confirm the result that a big boiler is necessary to heat the mold to high temperature rapidly. The energy consumption is too much for most economic production.

    中文摘要…………………………………………………………I 英文摘要………………………………………………………III 誌謝………………………………………………………………V 目錄………………………………………………………………VI 表目錄……………………………………………………………IX 圖目錄……………………………………………………………IX 第一章 緒論 1.1前言………………………………………………………………1 1.2研究目的…………………………………………………………3 1.3研究方法…………………………………………………………4 第二章 文獻回顧與研究流程 2.1 本研究相關文獻回顧…………………………………………6 2.1.1 微射出成型之研究回顧……………………………………6 2.1.2 變模溫製程之研究回顧……………………………………8 2.2本研究之研究流程……………………………………………10 第三章 電腦輔助工程分析 3.1 ANSYS基本架構與分析流程…………………………………14 3.1.1 元素、截面及材料定義……………………………………14 3.1.2 幾何圖形……………………………………………………15 3.1.3 網格化………………………………………………………15 3.1.4 邊界條件……………………………………………………15 3.1.5 模擬分析……………………………………………………16 3.1.6 分析結果……………………………………………………16 3.2 模穴承受射出壓力之應力分析………………………………16 3.2.1 分析模型……………………………………………………17 3.2.2 元素形式……………………………………………………18 3.2.3 材料性質……………………………………………………19 3.2.4 邊界條件……………………………………………………19 3.2.5 分析結果……………………………………………………20 3.3 模穴快速加熱之熱傳分析……………………………………21 3.3.1 分析模型……………..……………………………………21 3.3.2 元素形式…………….…………………………………….22 3.3.3 材料性質……………………………………………………22 3.3.4 邊界條件……………………………………………………23 3.3.5 分析結果……………………………………………………24 第四章 實驗設備介紹 4.1 塑膠模具………………………………………………………25 4.2 加熱設備………………………………………………………32 4.3 射出設備………………………………………………………34 第五章 實驗結果與模擬分析比對 5.1 ANSYS模擬……………………………………………………35 5.2 實驗結果………………………………………………………37 5.3 實驗結果與模擬分析比對……………………………………37 5.4 田口分析模擬與望大值………………………………………38 第六章 結論與未來展望 6.1 結論..…………………………………………………………54 6.2 未來展望………………………………………………………56 參考文獻……………………………………………………………57 附錄A ANSYS應力分析batch file………………………………61 附錄B ANSYS熱傳分析 batch file……………………………63 附錄C PUMP規格書…………………………………………………67 附錄D 電磁閥規格書………………………………………………68 附錄E 馬達規格書…………………………………………………70 附錄F 飽和水的熱物性……………………………………………73 中文索引……………………………………………………………74 作者自介……………………………………………………………76

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