| Summary: | 碩士 === 國立臺北科技大學 === 機電整合研究所 === 102 === For injection molding production, the insert molding is a common way to make multi-component product. More specific, to keep some strength, a metal insert with plastic injection is very popular in industry. However, due to the physical properties are so different between metal and plastic, it is so often to encounter many defects during the processing, such as short shot, warpage, and so on. In order to realize what happens during the insert molding, in this study we have applied Moldex3D CAE software to perform the simulation analysis.
Specifically, the experimental design of Taguchi method is used to explore the runner, gate design and process parameters to obtain the optimal molding density. L8 (27) orthogonal array was used to implement the noise experiments. Results show that the packing pressure and pressure time are the most important noise factors. Furthermore, these two factors (packing pressure and packing time) are combined into a composite noise factor. In main experiment, L9 (34) orthogonal table was used for measuring the molding density. Results show that the most important factors affecting the molding density are the pressure time and packing pressure. Analysis of variance was used for pooling of errors of S/N ratio and the quality characteristics. Results show that the important factors of the molding density are entirely consistent the results by Taguchi method under a confidence level of 98%. Finally, the confidence intervals were calculated to evaluate the errors of the factors. Results also show that the predictive value and experimental one are in a very good agreement. It indicates that our studied results are accurate enough. Moreover, through the real experimental testing from factory, the pull-off torque of the product has significantly improved after the optimization of process parameters (increased from 7.14 N-m to 7.31 N-m).
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