The Analysis in Minimizing Warpage of a Motorcycle Side Cover

• Main Authors: Yi-Cheng Huang, 黃義成
• Other Authors: Wern-Shiarng Jou
• Format: Others
• Language: zh-TW
• Published: 2008
• Online Access: http://ndltd.ncl.edu.tw/handle/18681458319798752517

碩士 === 國立高雄應用科技大學 === 模具工程系碩士班 === 96 === Since the demand for appearance is high today、the design of a motorcycle is more complicated than before. The plastic offers the low cost and diversified appearance of a motorcycle、however、the difficulty in injection molding can not be avoided. Recently、computer technology and auxiliary software are well developed. Simulation shorten the mold developing time and solve the problem in mass production、therefore、the mold flow simulation has been applied in the domestic motorcycle manufacturers to assist the design and development of motocycle. Since the motorcycle side cover is warpped and shrinked while injection molded、this research is aimed at solving the warpage problem of the motorcycle's side cover、investigating the mold design、and optimizing the molding conditions. At first、the short-shot experiment has been applied to check the consistence between experiment and simulation. Then、the Taguchi Method was applied to design the injection molding and simulation experiment and to compare the trend of the experimental with the simulation result. The control factors include mold temperature、melt temperature、injectaiom rate、packing pressure、packing profile、and coolant Reynolds number. Finally、parameter design was applied to analyze and compare the result of various designs and to find the most suitable design parameter. According to result、the wave front of the short-shot experiments and simulation result is about 90% matched. The difference between the volume of injection molded product and the volume of simulation result is only 0.1%. The significant factors of the experiement and simulation are the same also. The indicates that the mold flow simulation is accurate. The optimal molding conditions include mold temperature at 70℃、melt temperature at 190℃、injection rate at 70%、packing pressure at 90 MPa.、the first kind packing profile、and coolant Reynolds number at 2000. The amount of warpage is reduced from 16 mm to 9.9 mm and about 37% less. The control factors according to their significance are listed below: the coolant Reynolds number、the melt temperature、and the packing pressure. Therefore、cooling evenly will solve the uneven shrinkage problem and reduce the warpage.