研究生: 韋仁旌
研究生(英文姓名): Ran-Jing Wei
論文名稱: 以熱處理方式消除射出成型製品殘留應力之研究
英文論文名稱: The research of Reduce residual stress of plastic piece by heat treatment
指導教授: 徐瑞坤
指導教授(英文姓名): Ray-Quan Hsu
學位類別: 碩士
校院名稱: 國立交通大學
系所名稱: 機械工程系所
學號: 9514503
學年度: 96
語文別: 中文
論文頁數: 97
關鍵詞: 塑膠 ; 射出成型 ; 殘留應力 ; 熱處理
英文關鍵詞: Plastic ; Injection Molding ; Residual stress ; Heat treatment
[ 摘要 ]
塑膠製品由於較金屬產品輕，且有良好的強度，成型又容易，因此廣泛用於各項產業中，如電子產業、汽車產業等等。而隨著材料品質的改良，近年來亦大量應用在光學產業以及精密機械產業。塑膠射出成型是塑膠製品最常用的製造方法，射出成型製程的最大優點在於一次製程中可直接做出各種複雜外型的製品，但由於成型過程中溫度的劇烈變化，外觀問題（如結合線）與殘留應力產生變成不可避免的缺陷。殘留應力除了影響尺寸精度，也會在二次加工上發生問題。
本研究主要之目的即為研究塑膠製品於射出成型冷卻後，使用熱處理之方式，達到鬆弛塑膠製品之殘留應力，改善塑膠製品射出成型時產生之殘留應力現象。實驗時改變不同熱處理時間，並以光彈法觀測計算熱處理前後試片之等效應力值。實驗結果顯示塑膠試片於不同熱處理時間後，其等效應力降低效果隨著時間增加而遞減，並且以熱處理方式消除塑膠試片之殘留應力有其極限。再觀察PC材料實驗數據可以得知，熱處理效果隨厚度增加而增加，但是PS材料則沒有明顯此關係，並且比較非結晶與半結晶性塑膠，可以發現半結晶性塑膠之熱處理效果較差，原因推斷為不平均之結晶作用導致抵銷熱處理之好處，並且使熱處理效果較不穩定。
關鍵字：塑膠、射出成型、殘留應力、熱處理
[ 英文摘要 ]
Because the desity of plastics is lighter than metals ,besides, plastics possesses good strength and easy to form complicated shapes . It is generally used in almost every industry , including electronics , automobile and motorcycle industries ,etc. The improvement of plastic materials , It is also extensively used in optics and precise machinery. Injection molding process is a general process to fabricate plastic products. The advantages of injection molding process includes fabricating complex shapes in one process. However, since in the injection process, the material experience drastic changes in temperature , the problems of appearance and residual stress is hard to prevent. The residual stress influence not only the dimensions ,but also the second finish process.
The major purpose of this research is to heat treat the plastic specimen after injection molding process to reduce the residual stress caused during injection molding process. The specimens were put under different heat treatment process and the equivalent stress of each plastic specimen were calculated by Photoelastic stress analysis. After Analyze the plastic specimens after different heat treatment time , we found the effect of heat treatment decreasing with the increasing time. There is a limitation of decreasing the residual stress of plastic specimens by heat treatment in certain temperature. After analyze the data of PC material, we found the thicker the plastic specimens is, the better the effect of reducing residual stress by heat treatment is. But the PS material did not exhibit such an apparent relation. After comparing the crystalline and amorphous plastic material, we found the effect of reducing residual stress of crystalline plastic material is worse than amorphous plastic material. The reason about this may come from the unequally crystallization of the amorphous plastics reducing the effect of heat treatment. And the unequally crystallization effect cause the unstable effect of reducing residual stress by heat treatment.
Keyword：Plastic, Injection Molding, Residual stress, Heat treatment
[ 論文目次 ]
第一章 序論 1
1-1 研究背景 1
1-2 研究動機 2
1-3 研究目的 4
第二章 文獻回顧 6
2-1 殘留應力簡介 6
2-2 射出成型簡介 7
2-2-1 射出成型機規格 8
2-2-2 傳統射出成型步驟 8
2-2-3 成形條件之各階段重點 9
2-3 射出成型製品殘留應力成因 10
2-4 目前降低殘留應力之方式 12
2-5 調整射出成型之參數降低殘留應力之方式 13
2-5-1 射出壓縮成型與高速射出成型機 15
2-6 熱處理方式降低殘留應力之原理 16
2-7 塑膠之熱處理文獻回顧 17
2-7-1 不同熱處理溫度影響材料物理與機械性質 17
2-7-2 以holographic interferometry觀察熱處理之塑件 18
2-7-3 熱處理對於機械性質與結晶度之影響 19
2-7-4 分析比較熱處理前後試片機械、物理性質之變化 19
2-7-5 射出成型模擬研究 20
2-8 以光彈法進行應力分析之原理 21
2-8-1 光的電磁波性質 21
2-8-2 偏振光（Polarized Light） 22
2-8-3 平面偏光板（Plane Polarizers） 23
2-8-4 雙折射（Birefringence） 23
2-8-5 垂直入射下的二維應力光學定律 24
2-8-6 剪應力差積分法（shear-difference method） 26
第三章 射出成型與熱處理階段模擬 37
3-1 模擬方法概述 37
3-2 模擬軟體介紹 37
3-2-1 3D TIMON 塑料模流分析系统 37
3-2-2 ABAQUS之簡介 38
3-3 分析模型之前處理 40
3-3-1 幾何模型之建立 40
3-3-2 材料性質 40
3-4 射出成型與熱處理階段模擬 43
3-4-1模擬條件 43
3-4-2 網格劃分 43
3-4-3 射出成型與熱處理階段模擬結果 43
3-5 試片升溫階段模擬 45
3-5-1模擬條件 45
3-5-2 網格劃分 45
3-5-3 模擬結果 46
第四章 實驗規劃與流程 57
4-1 實驗規劃 57
4-1-1 測試實驗 57
4-1-2 試片熱處理實驗步驟 58
4-2 實驗試片 58
4-2-1 試片尺寸 58
4-2-2 實驗材料 59
4-3 實驗設備 59
4-3-1 射出成型之模具 59
4-3-2 光彈應力觀測儀器 59
4-3-3 加熱爐 59
第五章 實驗結果分析與討論 67
5-1 實驗數據分析概述 67
5-2 PC材料 67
5-3 PC材料二次熱處理 69
5-4 PS材料 71
5-5 PC材料試片結果分析 72
5-5-1 PC不同厚度試片之討論 72
5-5-2 PC材料結果分析 73
5-6 PS材料試片結果分析 74
5-6-1 PS材料不同厚度試片之討論 74
5-6-2 PS材料結果分析 75
5-7 PC材料與PS材料之分析比較結論 76
第六章 未來展望 94
參考文獻 95
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