光彈模擬技術在射出成型參數最佳化之應用研究

Abstract

塑膠產品被廣泛應用於各式各樣、各行各業的物品之中，在其外觀或是結構件上扮演著重要的角色。隨著塑膠材料品質的不斷改良與新種類的持續開發，塑膠材料更加廣泛應用在高精度機械裝置與其零件方面，且需求日益增加。然而塑膠元件卻還存在著許多問題大大地影響成品品質的好壞。 本研究主要目的為研究塑膠製品於射出成型製程中所形成之殘留應力，並找出各項交工參數對於殘留應力與翹曲的影響程度，及其相關性，並進行模流分析參數最佳化的分析流程，改善射出成形件的殘留應力與翹曲等問題的。本研究使用3D模流分析軟體Moldex3D與田口氏實驗法，分別以長方形薄板及機器人足部零件作為分析範例模型，系統化規劃各項射出成型交工參數來進行模擬分析。在殘留應力的觀測上，採用實體模型的剖面顯示技術模組，觀察表面與非表面區域的應力分佈。本研究並應用光彈模擬技術分析與觀測模型內部殘留應力的分佈區域與梯度變化，藉此觀察、分析殘留應力與翹曲變形之間的相關性，找出參數之最佳組合，期望在保持理想外觀的前提下，亦能改善塑膠製品射出成型後因殘留應力所影響的環境效應、光學性質、二次加工等各項問題。 根據本研究的分析結果，在射出時間、融膠溫度、保壓時間、冷卻時間、保壓壓力與射出壓力等六個射出成型加工參數中，歸納出以射出時間與融膠溫度對殘留應力的影響最為顯著；冷卻時間與保壓壓力則影響翹曲最大。利用這些影響程度整合歸納出一組加工參數的最佳組合，並透過模擬分析結果驗證、確認此參數組合對於範例模型改善殘留應力與翹曲等課題達到最佳設計效果。

The plastic products are widely used in many items in all walks of life. They play an important role in those appearance and structural parts. With the improvement of the quality of plastic materials and the new method of the plastic material technique appear, the plastic products are used in high-precision mechanical devices and spare-parts more and more widely. However, there are many problems still affect the quality. The main purpose of this study wants to research the residual stress of the plastic products after the injection molding manufacturing process, find the effect of the manufacturing conditions and the relationship. Then create a process of optimization for both residual stress and warpage. Using the 3D moldflow analysis software - Moldex3D and Taguchi’s experimental method and controlling the manufacturing conditions to analyze the rectangular sheet and the part of robot foots. To Observes the residual stress, we use the simulation photoelastic method to analyze the distribution of the residual stress. Therefore, find and analyze the relationship of the residual stress and warpage. Expect to maintain the ideal shape and can also improve the residual stress and warpage after the injection molding manufacturing process of plastic products. According to this paper, in the injecting time, melting temperature, packing time, cooling time, packing pressure, and injecting pressure, the manufacturing conditions have the most effective to residual stress are injecting time and melting temperature. The manufacturing conditions have the most effective to warpage are cooling time and packing pressure. Using these relationships, we can generalize a batter combination of manufacturing conditions to optimize both residual stress and warpage.