近年來由於纖維強化塑膠（FRP）材料已成為主要的輕量化技術之一，並已廣泛地應用在工業上，尤其是在汽車及航太產業中。然而，纖維之所以能夠增強塑膠，是因為它們的微結構特性，而在這些微結構特性中，纖維排向是最主要影響之因素。然而，在FRP基質內部的纖維排向非常複雜，通常不易透視，故不易掌握。另外，在射出成型製程中，熔膠流動與纖維之間可能存在一些交互作用，此等交互作用可能還會進一步受到材料黏彈性的影響，此等複合交互作用如何影響製程與產品，目前尚未完全了解。因此，在本研究中，我們嘗試使用具有三個ASTM D638標準拉伸試片的幾何系統研究流動-纖維耦合效應與黏彈性之間的交互作用對FRP的影響。我們的研究方法主要是同時應用CAE模擬分析與實驗觀察兩種方式。結果顯示，透過觀察Moldex3D模擬分析之流場分布，在有/無流動-纖維耦合效應情況下，發現在有耦合效應下，流動波前會出現凸-平-凹的現象；但在無耦合效應下，流動波前會出現凸-平-平的現象；此等流動波前明顯變化為流動-纖維耦合效應之展示，其與文獻的結果一致。再者，透過微觀纖維排向進行深入探究，我們將模擬系統分成四組，分別為：(1) 基本組：沒有考慮耦合及黏彈性效應；(2) 耦合效應組:單純考慮耦合效應；(3) 黏彈性效應組:單純考慮黏彈性效應；(4) 耦合加黏彈性效應組:同時考慮耦合及黏彈性效應。期間，各組比較以組別(1)作為比較之基準組。結果顯示，耦合組在纖維排向預測上與實驗數據最為接近；耦合加黏彈性效應組差異最大；至於黏彈性效應組的部分模擬分析結果與實驗趨勢相近，但整體趨勢而言，仍以耦合效應組與實驗的結果吻合度最高，因此我們認定射出成品內之纖維排向變化，最主要仍以流場引導，再加上流動-纖維耦合效應所導致。另外，為了證明流動-纖維耦合效應，我們進一步從射出成品之區域幾何尺寸變化進行細部觀察與研究。在此部份，我們將射出成品Model I 及Model II個別分成(NGR、CR、EFR)三區，每一區再細分成五小區，同步利用模擬分析與實驗方式(利用電腦斷層掃描加上影像處理分析技術)完成纖維排向張量之驗證，再以驗證後之模擬分析纖維排向結果估算出五小區之平均纖維排向張量值及其整體變化量。再者，我們也針對射出成品Model I 及Model II個別分成(NGR、CR、EFR)三區進行幾何尺寸變化(稱之收縮率)量測，經過詳細比對幾何尺寸變化趨勢與射出成品內在之平均纖維排向張量變化行為相當一致。此等結果應該足以說明流動-纖維耦合效應的存在與其從內而外之影響。

In recent years, fiber reinforced plastic (FRP) materials have become one of the main lightweight technologies and have been widely used in industry, especially in the automotive and aerospace industries. However, the reason why fibers can reinforce plastics is because of their microstructural properties, and among these microstructural properties, the fiber orientation is the most important factor to influence the system. However, the fibers’ behavior inside the FRP matrix is very complicated, and it is usually not easy to be observed. In addition, during the injection molding process, there may be some interactions between the melt flow and the fibers. These interactions could be further affected by the viscoelastic effect of the materials. In addition, how these complex interactions will further affect the process and products is not yet fully understood. Therefore, in this study, we have tried to use a geometric system with three ASTM D638 standard tensile bars to conduct the influence of the interaction between the flow-fiber coupling effect and viscoelastic effect on FRP.  Both CAE simulation analysis and experimental observation were utilized as the study methods. The results show that with considering the flow-fiber coupling effect, it is found that with the coupling effect the flow melt front exhibits  the convex-flat-concave flow phenomenon; but without considering the coupling effect, it shows  the convex-flat-flat type. This significant difference is one of the evidences caused by the flow-fiber coupling effect. This result is consistent with that observation by the literature[17]. Furthermore, in order to understand how the flow-fiber coupling effect influence the fiber orientation in injection molding, there are four different group systems have been considered, namely: (1) Basic group: without considering flow-fiber coupling and viscoelastic effects; (2) Coupling effect group: considering the flow-fiber coupling effect only; (3) Viscoelastic effect group: considering the viscoelastic effect only; (4) Coupling plus viscoelastic effects group: considering both flow-fiber coupling and viscoelastic effects at the same time. The simulation results of injection molding processes based on those four groups have been further investigated. The results show that the simulation results of the Coupling effect group are closest to the experimental observation in fiber orientation distribution. Although the results of the Viscoelastic effect group are also consistent with that of experimental observation, but they are not as good as that of the Coupling group.  While the simulation results of the both flow-fiber coupling and viscoelastic effects group are not good enough.  Based on these results, the flow-fiber coupling effect is significantly verified.  Moreover, to realize how flow-fiber coupling effect can further influence the quality of the injected parts, the dimensions of the injected parts have been measured.  Specifically, the Model I and Model II (ASTM D638 specimens), each one has been divided into three regions, named near gate region (NGR), center region (CR), and end of filling region (EFR). For each region, the three directional side dimensions have been measured using five smaples each time. Then the average dimension for each side of each region has been recorded.  Moreover, the details of the average fiber orientation distribution have been discovered by divided each region into five sub-regions.  The correlation between the average fiber orientation distribution with considering the flow-fiber coupling effect and the three directional dimension variations of each region can be constructed.  For example, in the NGR of the Model I, from upstream to downstream, the A11 fiber orientation tension is getting larger, the A22 is smaller.  From the side dimension measurement of Model I, the dimension in the flow direction becomes larger, and the dimension in the cross-flow direction becomes smaller.  The results show that the fiber orientation variation is consistent with that of the dimensional change for Model I at NGR.  Similarly, the relation can also be observed in other regions in Model I, and regions in Model II.  Based on these results, the flow-fiber coupling effect can be further validated.

致謝	I
中文摘要	II
英文摘要	IV
目錄	VII
圖目錄	X
表目錄	XVII
符號說明	XVIII
第一章	緒論	1
1.1	前言	1
1.2	文獻回顧	2
1.2.1纖維強化塑膠	2
1.2.2文獻總結	5
1.3	研究動機與目的	5
1.4	論文架構	6
第二章	射出成型纖維複合材料之維結構特性及熔膠流動-纖維耦合效應介紹	9
2.1	塑膠射出成型製程之流程介紹	9
2.2	高分子材料介紹	12
2.2.1 聚丙烯	13
2.2.2纖維複合材料之纖維強化塑膠	13
2.3纖維之微結構介紹	14
2.3.1纖維排向	14
2.3.2纖維長度	16
2.3.3纖維濃度	16
2.4熔膠流動-纖維耦合效應介紹	17
第三章	研究方法與流程	19
3.1	研究方法與流程	19
3.2	CAE模擬分析與系統資訊	22
3.2.1 基本理論	22
3.2.2 射出成品幾何與模具設計	30
3.2.3 模擬分析之網格模型建構	32
3.2.4 材料選擇	37
3.2.5 CAE模擬分析之成型條件設定	41
3.2.6 CAE模擬分析之量測節點位置設計	42
3.2.7 CAE模擬分析使用之硬體及系統	44
3.2.8 CAE模擬分析使用之軟體	44
3.2.9 CAE模擬分析之專案建立	44
3.2.10 CAE模擬分析之參數設定	45
3.3	實驗研究與相關資訊	46
3.3.1 射出機台系統與相關設備	46
3.3.2 射出成品之幾何尺寸(收縮率)變化量測定義與方法	49
3.3.3 Model I至Model III 機械特性初步探討	52
3.3.4 射出成品之電腦斷層掃描(CT scan)	55
第四章	結果與討論	58
4.1 CAE模擬分析之流動行為探討	58
4.1.1有/無考慮流動-纖維耦合效應影響下的流動行為	58
4.1.2有/無考慮流動-纖維耦合效應影響下的流場分布行為比較	59
4.2熔膠流動-纖維耦合效應與材料黏彈性交互作用對微觀纖維排向影響之探討	61
4.2.1流動-纖維耦合效應對纖維排向之影響	61
4.2.2材料黏彈性效應對纖維排向之影響	70
4.2.3流動-纖維耦合效應與材料黏彈性效應對纖維排向之影響	78
4.3微觀纖維排向與射出成品局部尺寸變化(收縮率)之關聯性探討		86
4.3.1單一區域之微觀纖維排向變化	87
4.3.2纖維排向變化與尺寸變化(收縮率)之關聯性探討	103
第五章	結論	114
第六章	未來研究方向	116
第七章	參考文獻	117
第八章 附錄	123
作者簡歷	123
 
圖目錄
圖2-1. 射出成型週期[27]	11
圖2-2. 模穴內厚度方向之纖維排向分布圖[32]	15
圖2-3. 模擬纖維排向示意圖[33]	16
圖2-4. CAE模擬有/無考慮流動-纖維耦合效應下流場之比較[17]	18
圖3-1. 研究流程	21
圖3-2 單根纖維排向向量P之定義圖[11]	25
圖3-3. 成品幾何模型(單位: mm)	31
圖3-4. 拉伸試片尺寸(單位: mm)	31
圖3-5. 模座及冷卻水路配置(單位: mm)	32
圖3-6. 網格種類[43]	32
圖3-7. 網格元素解析度與溫度場分布[42]	33
圖3-8. 不同層數網格之進澆口壓力曲線	35
圖3-9. 本研究之實體網格內部構造示意圖	36
圖3-10. 網格品質探討	37
圖3-11. SF材料黏度對剪切率之關係圖[44]	39
圖3-12. SF材料比容對溫度在不同壓力之關係圖[44]	39
圖3-13. SF材料比熱對溫度之關係圖[44]	40
圖3-14. SF材料熱傳導係數對溫度之關係圖[44]	40
圖3-15. 微觀結構量測節點	43
圖3-16. 針對單一區域觀察之微觀結構量測節點	43
圖3-17. CLF-180TXL射出機台	47
圖3-18. 實驗之模具(a)公模，(b)母模	47
圖3-19. NGR、CR、EFR區域之量測長度定義	49
圖3-20. 電子式游標尺	50
圖3-21. 實際射出成品幾何尺寸(收縮率)量測示意圖(a)量測X方向量，(b)量測Y方向，(c)量測Z方向	51
圖3-22. HT-9102M拉伸機台[46]	52
圖3-23. 拉伸試片尺寸示意圖[46]	53
圖3-24. 射出成品機械強度比較(本次進行的拉伸實驗)	54
圖3-25. 射出成品機械強度比較(文獻資料)[46]	54
圖3-26. Model I電腦斷層掃描實驗結果圖[47]：(a) NGR區域，(b) CR區域，(c) EFR區域	57
圖4-1. CAE模擬分析:沒有考慮跟有考慮流動-纖維耦合的流動波前比較圖	58
圖4-2. CAE模擬流場分布結果比較：(a)沒有考慮流動-纖維耦合情況，(b)有考慮流動-纖維耦合	60
圖4-3. Model I在NGR之纖維排向：(a)基本組模擬結果，(b)耦合效應組模擬結果，(c)實驗結果	63
圖4-4. Model I在CR之纖維排向：(a) 基本組模擬結果，(b) 耦合效應組模擬結果，(c)實驗結果	64
圖4-5:Model I在EFR之纖維排向：(a)基本組模擬結果，(b)耦合效應組模擬結果，(c)實驗結果	65
圖4-6. Model II在NGR之纖維排向：(a)基本組模擬結果，(b)耦合效應組模擬結果，(c)實驗結果	66
圖4-7. Model II在CR之纖維排向：(a)基本組模擬結果，(b)耦合效應組模擬結果，(c)實驗結果	67
圖4-8. Model II在EFR之纖維排向：(a)基本組模擬結果，(b)耦合效應組模擬結果，(c)實驗結果	69
圖4-9. Model I在NGR之纖維排向：(a)基本組模擬結果，(b)黏彈性效應組模擬結果，(c)實驗結果	71
圖4-10. Model I在CR之纖維排向：(a)基本組模擬結果，(b)黏彈性效應組模擬結果，(c)實驗結果	72
圖4-11. Model I在EFR之纖維排向：(a)基本組模擬結果，(b)黏彈性效應組模擬結果，(c)實驗結果	73
圖4-12. Model II在NGR之纖維排向：(a)基本組模擬結果，(b)黏彈性效應組模擬結果，(c)實驗結果	74
圖4-13. Model II在NGR之纖維排向：(a)基本組模擬結果，(b)黏彈性效應組模擬結果，(c)實驗結果	76
圖4-14. Model II在NGR之纖維排向：(a)基本組模擬結果，(b)黏彈性效應組模擬結果，(c)實驗結果	77
圖4-15. Model I在NGR之纖維排向：(a)基本組模擬結果，(b)耦合加黏彈性效應組模擬結果，(c)實驗結果	79
圖4-16. Model I在CR之纖維排向：(a)基本組模擬結果，(b)耦合加黏彈性效應組模擬結果，(c)實驗結果	80
圖4-17. Model I在EFR之纖維排向：(a)基本組模擬結果，(b)耦合加黏彈性效應組模擬結果，(c)實驗結果	81
圖4-18. Model II在NGR之纖維排向：(a)基本組模擬結果，(b)耦合加黏彈性效應組模擬結果，(c)實驗結果	82
圖4-19. Model II在CR之纖維排向：(a)基本組模擬結果，(b)耦合加黏彈性效應組模擬結果，(c)實驗結果	84
圖4-20. Model II在EFR之纖維排向：(a)基本組模擬結果，(b)耦合加黏彈性效應組模擬結果，(c)實驗結果	85
圖4-21. Model I NGR(在B1量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	88
圖4-22. Model I NGR(在B2量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	88
圖4-23. Model I NGR(在B3量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	89
圖4-24. Model I NGR(在B4量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	89
圖4-25. Model I NGR(在B5量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	89
圖4-26. Model I CR(在E1量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	91
圖4-27. Model I CR(在E2量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	91
圖4-28. Model I CR(在E3量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	91
圖4-29. Model I CR(在E4量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	92
圖4-30. Model I CR(在E5量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	92
圖4-31. Model I EFR(在H1量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	94
圖4-32. Model I EFR(在H2量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	94
圖4-33. Model I EFR(在H3量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	94
圖4-34. Model I EFR(在H4量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	95
圖4-35. Model I EFR(在H5量測點)之纖維排向：(a)耦合效應組模擬結果，(b)實驗結果	95
圖4-36. Model II NGR(在B1量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	96
圖4-37. Model II NGR(在B2量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	97
圖4-38. Model II NGR(在B3量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	97
圖4-39. Model II NGR(在B4量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	97
圖4-40. Model II NGR(在B5量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	98
圖4-41. Model II CR(在E1量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	99
圖4-42. Model II CR(在E2量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	99
圖4-43. Model II CR(在E3量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	100
圖4-44. Model II CR(在E4量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	100
圖4-45. Model II CR(在E5量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	100
圖4-46. Model II EFR(在H1量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	102
圖4-47. Model II EFR(在H2量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	102
圖4-48. Model II EFR(在H3量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	102
圖4-49. Model II EFR(在H4量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	103
圖4-50. Model II EFR(在H5量測點)之纖維排向: (a)耦合效應組模擬結果，(b)實驗結果	103
圖4-51. Model I NGR區域(從B1至B5區域)模擬分析之A11、A22、A33纖維排向平均值	104
圖4-52. Model I NGR區域射出成品之幾何尺寸變化示意圖	105
圖4-53. Model I CR區域(從E1至E5區域)模擬分析之A11、A22、A33纖維排向平均值	106
圖4-54. Model I CR區域射出成品之幾何尺寸變化示意圖	106
圖4-55. Model I EFR區域(從H1至H5區域)模擬分析之A11、A22、A33纖維排向平均值	108
圖4-56. Model I EFR區域射出成品之幾何尺寸變化示意圖	108
圖4-57. Model II NGR區域(從B1至B5區域)模擬分析之A11、A22、A33纖維排向平均值	109
圖4-58. Model II NGR區域射出成品之幾何尺寸變化示意圖	110
圖4-59. Model II CR區域(從E1至E5區域)模擬分析之A11、A22、A33纖維排向平均值	111
圖4-60. Model II CR區域射出成品之幾何尺寸變化示意圖	111
圖4-61. Model II EFR區域(從H1至H5區域)模擬分析之A11、A22、A33纖維排向平均值	113
圖4-62. Model II EFR區域射出成品之幾何尺寸變化示意圖	113
 
表目錄
表3-1. 本研究之網格系統資訊	35
表3-2. 材料資訊	38
表3-3. 材料性質資訊[45]	38
表3-4. CAE模擬分析成型條件之參數設定	41
表3-5. iARD-RPR model之參數設定	46
表3-6. 修正IISO viscosity model之參數設定	46
表3-7. 射出機台相關資訊	47
表3-8. NGR、CR、EFR區域之原始設計長度	50
表3-9. Mitutoyo電子式游標尺規格及相關資訊	50
表3-10. 拉伸試片相關尺寸[46]	53
表4-1. 實驗量測Model I NGR收縮值	105
表4-2. 實驗量測Model I CR收縮值表	107
表4-3. 實驗量測Model I EFR收縮值	108
表4-4. 實驗量測Model II NGR收縮值	110
表4-5. 實驗量測Model II CR收縮值	112
表4-6. 實驗量測Model II EFR收縮值	113

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