薄殼產品及高倍數光碟片的模具水路改良與製程最佳化

Abstract

在現今的塑膠工業中，大部份的塑膠產品都是利用射出的方式來製造，而光碟片便是經由塑膠射出的方式產生出成品的典型範例。影響光碟片特性的參數很多，但影響程度有所不同，因此，如果在模具設計前，能先進行模擬的分析與驗證，利用電腦輔助工程分析輔助找尋到各參數之間的相互影響關係，則不僅可以降低產品設計時之工時和成本，而且也可以在模擬階段就將射出會發生的問題進行改良，使產品順利生產。 關於熱傳導效率，模具之冷卻水路是影響翹曲值最大的因素之一。而本研究中，就先利用電腦輔助工程設計了多種不同尺寸和深度的冷卻水路，找尋出翹曲值最小之最佳化冷卻水路，其次利用田口實驗法找尋出最佳化射出參數，最後使用實作之上機實驗，去驗證電腦輔助工程的準確性。而結果發現當水路深度越小時，和不同水路搭配下，可獲得更小的翹曲值。 本研究主題以光碟片的模擬分析為基礎，針對3C光機電產品的塑膠薄殼組件，利用電腦輔助工程進行模流分析，分析射出、保壓、冷卻、翹曲等。在分析完成後，再配合田口實驗法則來求出製程最佳化的參數，修改硬體設備：模具鏡面冷卻水路，調整軟體方面：射出速度、射出壓力、溫度、鎖模力，達成產品的生產效能提升。

In the plastics industry, most of the products are produced by using the way of injection. The optical disc is one of the typical model that is formed through injection molding process. There are many parameters can influence the disc character, but influence levels are different. Hence, if we can preview the results based on the analysis and simulation method, to find out the influence effect of each parameter by using CAE software before the molding test, we can not only reduce the cycle time and the cost, but also improve the product quality. The mold cooling channel is one of the critical factors to influence warp value of the product. In this research, we use CAE tool assisting to evaluate design cases with various size and depth of the cooling channels, to find for the optimal design of cooling channel for minimizing the warp value. This study also adopts Taguchi experiment design method to find the optimal injection parameters. The arranged experiments were implemented to confirm the accuracy of the simulation results of CAE. The results showed that the smaller depth of the channel with hybrid cooling set the smaller the warp value. The research focus on the cooling channels design and optimal parameters study. In view of the thin shell optics products; we use the CAE mold-flow simulation software to analyze the injection problems including the study of packing pressure, cooling and warp value. Taguchi experiment design method is proposed as applying the orthogonal array of the parameters. The CAE method cooperating with Taguchi experiment method can provide useful data for modifying hardware equipment: mold mirror cooling channel, and can adjust software setting value: injection velocity, injection pressure, temperature, clamp force etc. This study provides several practical messages helping related industry to achieve a successful and high quality mass production.