擠出與射出成型.ppt

Plastic Forming: Extrusion and Injection Molding Similar to plastic forming technique, suitable for large scale, continuous production Extrusion of Ceramics 多半先將陶瓷粉末與高分子黏結劑粉末充分混合後, 才加入液體; 採用slurry方式混合, 然後脫去一些水 (過濾), 得到濾餅, 再進行擠出加工也可行 Extruded Shapes Flow in Extruder extruder: piston type or screw (single or twin) type兩大類 Extrusion Mechanics A Few Equations 當進料被壓縮到達飽和狀態時, 可用Herschel-Bulkley equation描述 Empirical Parameters 擠出機內的壓力分布 More Comments Twin Screw Extruder Control of Defects Insufficient strength and stiffness: cohesive strength當然與所添加的黏著劑密切相關, 適當強度才能後續加工處理 Control of Effects (2) Plunger Type Injection Molding Machine Compositions 多種黏著劑系統, 經常加入一種以上的黏著劑, 以提供理想的流變性為; viscosity 105 mPa.s on molding Material Variables 物料被射入模具內, may through multiple cavities; temperature control 很重要的一環 Mechanics of Flow 對於射出成型的配料, 一般用capillary viscometer零測其黏度與流變行為 (similar to injection molding) Defects and Control 許多工程上需要改進的地方, 需要許多經驗, 不完全可以模擬預測 Removal of Organics 因為有機物添加的很多, 所以它的燒除成為關鍵劑技術之一, 與製造成本密切有關; 可能成為速率控制步驟 * * Need quite some polymer additives, to make bahaviour similar to plastic materials Extruded products: tube, paltes (tile), brick, insulator (ring shape), catalyst extrudate (pellet) etc. Injected products: mostly small objects, and small, complex shape with thin walls Che5700 陶瓷粉末處理 High shear mixer is often needed; screw feeded也有不錯的混合效果 Che5700 陶瓷粉末處理 Honeycomb shape 是近年常見的擠出形狀之一; say 200 channel/cm2, wall thickness 0.1 mm; 組成中經常含有高量黏著劑, e.g. 35%, 在加工過程中多會收熱而呈熔融狀態, 離開模具後冷卻固化 Che5700 陶瓷粉末處理 取自JS Reed, 1995; 擠出程序的階段: (a) 進料, (b) consolidation and flow in the barrel, (c) 通過模具頭; (d) 通過die-land; (e) ejection; [有時候可能沒有die-land] 擠出系統壓力可達4 – 15 M Pa flow 來自三部分: (a) drag flow by screw surface; (b) pressure flow induce by axial gradient; and (c) leakage flow through clearance between barrel and outside diameter of screw 由於ceramic paste rheology is quite complex, 所以很難模擬. 除非使用Newtonian fluid model 在die內, 則僅為pressure flow 通過die後, relaxation of stress造成物件的些許改變(in terms of thickn