本技術報告主要分為兩大部分，第一部分為本人於三匠科技股份有限公司進行實務實習的成果及心得；第二部分為本次實務實習中所進行具有學術研究之陶瓷手機背蓋專案，其中針對該產品於開發過程遭遇翹曲變形問題，進行深入探討後所得之技術研究報告，精簡描述如下：近年來精密陶瓷的市場發展十分迅速，根據近期的市場調查評估，從2016年到2021年其市場將以6.5％的年複合成長率發展，而2021年則會成長到104億美元左右的規模。另一方面，現今時代正是第四代通訊技術要轉換為第五代通訊技術，為了克服訊號傳輸的問題，需要透過更換手機背蓋材料以改善此情況。而精密陶瓷正因具有良好且獨特性能的材料，剛好可以藉此克服雜訊干擾的問題。再則，因應市場需求，陶瓷射出成型目前已成為精密陶瓷零組件製作的主要方式之一。其製程主要分為四大階段，分別為：粉末與黏結劑的混煉、射出成型、熱脫脂與溶劑脫脂及高溫燒結。每個階段材料之成型行為若沒有好好地了解及掌控，產品可能會有毛邊、裂痕、翹曲變形…等缺陷發生。為此，本研究將針對陶瓷背蓋產品於射出製程所產生的翹曲變形進行探討，並藉由CAE模擬分析，研究內在造成變形之機制，並找出改善之方法；另外，也以實驗驗證確認模擬的正確性。詳細來說，我們將先透過CAE模擬進行產品設計診斷與確認，結果發現不論在充填或保壓結束時，背蓋R角的溫度皆會比其他部分高出60℃~70℃，我們推測這可能是R角造成溫度不均，進而引發翹曲變形的主要原因。接著我們將背蓋的R角移除並進行模擬，發現翹曲變形明顯減少，確立R角設計是造成背蓋翹曲變形的主要原因。再則，我們進一步希望透過改變R角末端厚度，探討定量調控產品翹曲變形之可能性，結果顯示當R角厚度由1.038 mm增加至1.638 mm時，其翹曲變形量也會由4.044 mm減少至0.208 mm。再者，我們採用Moldex3D軟體，經設置一系列量測節點，仔細測量R角上各位置的體積收縮率，找出R角上端與下端的體積收縮率差異是造成翹曲變形的主要原因。最後，我們也規劃並進行一系列之實驗驗證，其中原始設計(Model 1)的結果與模擬趨勢相符，而更改R角厚度設計的實驗，建議可做為未來的研究之一。

The main purposes of the practical training have two parts. Firstly, it allows me to get the chance to join the company to learn industrial technology in early age to understand the real company operation. Secondly, it helps me to join ACT-ARX Co. Ltd. to learn back-cover of cellphone which is made by ceramic. The main challenge is the warpage problem for this product during the processing. The details are as follows. The precision ceramics market is increased very rapidly in recent years. According to recent market research estimates, from 2016 to 2021, the precision ceramic market will grow at a compound annual growth rate of 6.5%, and in 2021 it will grow to a scale of about 10.4 billion US dollars. Additionally, during the past few years, the fourth generation of communication technology will be transferred into the fifth generation very soon. In order to overcome the problem of signal transmission, it is necessary to improve the situation by replacing the back-cover material of the mobile phone. Precision ceramics are one of the good candidates as the replacing materials with good properties that can overcome the problem of noise interference. Furthermore, to fit the market demands, ceramic injection molding has become one of the main methods to produce precision ceramic components. The process associated with those ceramic components is divided into four major stages, namely: mixing of powder and binder, injection molding, thermal degreasing and solvent degreasing, and high temperature sintering. If the molding behavior of each stage of the material is not well understood and controlled, the product may have defects such as burrs, cracks, warpage, etc. Specifically, in this study , we will discuss the warpage problem during the development of the ceramic back-cover product using the injection process. To analyze what the reason to cause the warpage problem, CAE simulation and experimental studies have been utilized. Results show that the temperature of the R-angle of the back cover was 60℃~ 70℃ higher than other parts at the end of filling or packing. We speculate that this may be the main cause for the warpage. Next, we tried to modify the R angle design and applied CAE simulation to predict the warpage behavior. The result showed that the warpage was reduced significantly. Therefore, It supports us about that the R angle design is the main cause of the back-cover warpage. Furthermore, we also tried to manage the amount of the warpage for the ceramic injection product by changing the thickness of the end of the R-angle. The results show that when the R angle thickness was increased from 1.038 mm to 1.638 mm, the amount of warpage could be reduced from 4.044 mm to 0.208 mm. Moreover, we have applied Moldex3D to analyze the warpage mechanism based on the volume shrinkage of certain measuring nodes. After recording and analysis on the volume shrinkages of those measuring nodes using Moldex3D, we found that the difference in volume shrinkage between the upper and lower sides of the R angle is the main source to generate warpage. Finally, we have also performed a series of experimental studies to verify. Results showed that the warpage behavior of the original design (Model 1) are consistent with that of the simulation prediction in the trend. Due to funding and timing, the experiment to change the R-angle thickness design is suggested for the future works if it is possible.

中文摘要 I
英文摘要 II
目錄	IV
圖目錄	IX
表目錄	XIII
實習機構簡介	1
實習內容概述	3
實習心得及自我期許	8
技術報告內容	10
第一章	緒論	10
1.1 前言	10
1.2 研究目的與動機	11
1.3 陶瓷粉末射出製程介紹	13
1.3.1	製程概述	13
1.3.2	混煉	13
1.3.3	射出成型	14
1.3.4	脫脂	15
1.3.4.1溶劑脫脂	15
1.3.4.2熱脫脂	15
1.3.5	燒結	16
1.4 論文架構	16
第二章	文獻回顧	18
2.1 回顧陶瓷粉末射出市場及近期概況說明	18
2.2 陶瓷粉末射出成型概念與技術	19
2.3 產品翹曲變形缺陷	21
第三章	研究方法與流程	23
3.1 研究方法與流程概述	23
3.2 CAE模擬方法	25
3.2.1 CAE專案規劃與建立	25
3.2.1.1 產品幾何尺寸與模具設計	26
3.2.1.2 網格類型之選定與建構	29
3.2.1.3 建立CAE模擬分析專案	30
3.2.2單一因子影響效應研究	33
3.2.3 產品幾何變化效應之研究	35
3.2.3.1 產品R角厚度定義	35
3.2.3.2 設計變更模型	36
3.2.3.3 溫度分布截面定義	38
3.2.4 產品翹曲變形量測方式建立	38
3.2.4.1 翹曲變形量測節點設置	38
3.2.4.2 體積收縮率量測節點設置	40
3.3 實務實驗方法	41
3.3.1 實驗專案建立	41
3.3.1.1實驗之機台與儀器	42
3.3.1.2 實際射出成型實驗參數設定	50
3.3.1.3 短射實驗研究之參數設定	51
3.3.2 產品翹曲變形量測方式建立	53
3.3.2.1 絕對翹曲變形量	53
3.3.2.2 相對翹曲變形量	53
第四章	結果與討論	55
4.1 CAE模擬分析	55
4.1.1 網格特性與收斂性探討	55
4.1.2 單一因子特性結果探討	58
4.1.3 CIM短射與整體流場特性探討	61
4.1.3.1 模擬短射結果	62
4.1.3.2 充填歷程分析	62
4.1.3.3 溫度分布結果整理	63
4.1.4 模擬翹曲量測結果	65
4.1.5 產品幾何變化效應研究	66
4.1.5.1有無R角機構對翹曲變形之影響分析	66
4.1.5.2 產品R角厚度變化效應研究	68
4.1.6 產品翹曲優化機制探討	70
4.2 實務實驗結果	72
4.2.1 短射實驗結果	72
4.2.2 實驗生胚翹曲變形量測結果	73
4.2.2.1 生胚絕對翹曲變形量量測結果	73
4.2.2.2 生胚相對翹曲變形量量測結果	77
4.2.3燒結後成品翹曲變形量量測結果	80
4.3 CAE模擬分析及實務實驗結果比較	83
4.3.1 短射實驗比較	83
4.3.2 生胚翹曲變形量測結果比較	87
4.3.3.1 模擬與生胚絕對翹曲變形量比較結果	87
4.3.3.2 模擬與生胚相對翹曲變形量比較結果	88
4.2.2.3 生胚翹曲變形趨勢比較	89
4.3.4 燒結後成品翹曲變形結果比較	91
第五章	結論	93
第六章	未來研究方向及建議	95
第七章	參考文獻	96
作者簡歷	98
圖目錄
　圖1.1 陶瓷射出成型流程圖   3
　圖1.2 2.5D影像量測儀   6
　圖1.3 AEROEL雷射測徑儀   7
　圖2 粉末射出流程圖   21
　圖3.1.1 研究流程圖   25
　圖3.2.1 手機背蓋產品幾何及尺寸   27
　圖3.2.2 流道尺寸圖   27
　圖3.2.3 模具尺寸示意圖   28
　圖3.2.4 冷卻水路尺寸示意圖   28
　圖3 2.5 材料黏度性質圖   32
　圖3.2.6 材料PVT性質圖   32
　圖3.2.7 計算參數設定   33
　圖3.2.8 厚度定義圖 (R角)   36
　圖3.2.9 模型R角厚度設計變更示意圖   37
　圖3.2.10 溫度分布截面定義圖   38
　圖3.2.11 量測節點分布上視圖   39
　圖3.2.12 量測節點分布側視圖   40
　圖3.2.13 體積收縮率量測節點示意圖   41
　圖3.3.1 百塑CIM-150T陶瓷粉末射出機   42
　圖3.3.2 手機背蓋實體產品模具圖   44
　圖3.3.3 SAGE WM-120模溫機   45
　圖3.3.4 溶劑脫脂槽   46
　圖3.3.5 陶瓷熱脫脂爐   47
　圖3.3.6 陶瓷高溫燒結爐   48
　圖3.3.7 高度規(使用電子高度計)   49
　圖3.3.8 電子高度計   50
　圖3.3.9 相對翹曲變形量量測方式示意圖   54
　圖4.1.1 組別A (Fast Cool) 網格模擬結果圖(×10)   57
　圖4.1.2 組別B (Solid Mold Base) 網格模擬結果圖(×10)   57
　圖4.1.3 組別C (BLM) 網格模擬結果圖(×10)   57
　圖4.1.4 網格組別比較實驗結果   57
　圖4.1.5 原始操作條件Z軸翹曲變形量圖   60
　圖4.1.6 單一因子分析－保壓時間對翹曲變形量影響圖   60
　圖4.1.7 單一因子分析－冷卻時間對翹曲變形量影響圖   61
　圖4.1.8 單一因子分析－模具溫度對翹曲變形量影響圖   61
　圖4.1.9 模擬短射結果   62
　圖4.1.10 充填歷程圖   63
　圖4.1.11 手機背蓋各層溫度分布情形   64
　圖4.1.12 溫度分布圖 ( EOF－Layer 1 )   65
　圖4.1.13 Model 1 (含R角)模擬分析結果 (×10)   67
　圖4.1.14 Model 2 (無R角)模擬分析結果 (×10)   67
　圖4.1.15 不同R角末端厚度(D2)模型分析結果 (×10)   69
　圖4.1.16 不同R角末端厚度(D2)與翹曲變形量趨勢   70
　圖4.1.17 不同R角末端厚度(D2)兩側體積收縮率差值比較   71
　圖4.2.1 短射實驗結果圖   73
　圖4.3.1 模擬及實驗短射圖比對 ( 充填比例10% )   83
　圖4.3.2 模擬及實驗短射圖比對 ( 充填比例20% )   84
　圖4.3.3 模擬及實驗短射圖比對 ( 充填比例38% )   84
　圖4.3.4 模擬及實驗短射圖比對 ( 充填比例47% )   84
　圖4.3.5 模擬及實驗短射圖比對 ( 充填比例58% )   85
　圖4.3.6 模擬及實驗短射圖比對 ( 充填比例65% )   85
　圖4.3.7 模擬及實驗短射圖比對 ( 充填比例78% )   85
　圖4.3.8 模擬及實驗短射圖比對 ( 充填比例82% )   86
　圖4.3.9 模擬及實驗短射圖比對 ( 充填比例90% )   86
　圖4.3.10 模擬及實驗短射圖比對 ( 充填比例100% )   86
　圖4.3.11 模擬與實驗生胚翹曲變形量比較表 (絕對翹曲變形量)  
 88
　圖4.3.12 模擬與實驗生胚翹曲變形量比較表 (相對翹曲變形量)  
 88
　圖4.3.13 Side I生胚翹曲變形量比較表   89
　圖4.3.14 Side II生胚翹曲變形量比較表   90
　圖4.3.15 Side III生胚翹曲變形量比較表   90
　圖4.3.16 Side IV生胚翹曲變形量比較表   91
　圖4.3.17 生胚及燒結品平均翹曲變形量比較圖   92
 
表目錄
　表1.3.1 黏結劑功能表   14
　表3.2.1 網格繪製參數比較表   30
　表3.2.2 單一因子分析－保壓時間效應操作條件表   34
　表3.2.3 單一因子分析－冷卻時間效應操作條件表   34
　表3.2.4 單一因子分析－模具溫度效應操作條件表   35
　表3.2.5 探討R角影響模型資訊表   37
　表3.2.6 設計變更模型資料表   37
　表3.3.1 百塑CIM-150T機台規格表   43
　表3.3.2 SAGE模溫機規格表   45
　表3.3.3 實驗參數表   51
　表3.3.4 短射實驗參數設定表   52
　表3.3.5 模擬及實驗各參考點a線段長度   54
　表4.1.1 模擬最佳參數表   56
　表4.1.2 模擬生胚翹曲變形值量測結果   66
　表4.1.3 不同R角末端厚度(D2)模型翹曲變形量比較表   69
　表4.1.4 不同R角末端厚度(D2)兩側體積收縮率差值比較   71
　表4.2.1 實驗生胚翹曲變形量量測結果 (Sample 1 絕對翹曲變形量)   74
　表4.2.2 實驗生胚翹曲變形量量測結果 (Sample 2 絕對翹曲變形量)   74
　表4.2.3 實驗生胚翹曲變形量量測結果 (Sample 3 絕對翹曲變形量)   75
　表4.2.4 實驗生胚翹曲變形量平均值 (絕對翹曲變形量)   75
　表4.2.5 生胚翹曲變形量標準差 (絕對翹曲變形量)   76
　表4.2.6 實驗生胚翹曲變形量量測結果 (Sample 1 相對翹曲變形量)   77
　表4.2.7 實驗生胚翹曲變形量量測結果 (Sample 2 相對翹曲變形量)   78
　表4.2.8 實驗生胚翹曲變形量量測結果 (Sample 3 相對翹曲變形量)   78
　表4.2.9 實驗生胚翹曲變形量平均值 (相對翹曲變形量)   79
　表4.2.10 生胚翹曲變形量標準差 (相對翹曲變形量)   79
　表4.2.11 實驗燒結品翹曲變形量量測結果 (Sample 1 相對翹曲變形量)   80
　表4.2.12 實驗燒結品翹曲變形量量測結果 (Sample 2 相對翹曲變形量)   81
　表4.2.13 實驗燒結品翹曲變形量量測結果 (Sample 3 相對翹曲變形量)   81
　表4.2.14 實驗燒結品翹曲變形量平均值 (相對翹曲變形量)   82
　表4.2.15 燒結品翹曲變形量標準差 (相對翹曲變形量)   82

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