近年來由於人口增長過快，導致環境嚴重污染，尤其是二氧化碳的排放。為了減少CO2的排放問題，其中在汽車製造上，以塑膠代替鋼材，是有效降低排放量的方法之一。但是，由於塑料基材內部纖維的流動非常複雜，因此不容易可視化及管理。具體而言，從纖維的微觀結構到最終產品的巨觀機械性質之間的關聯性是我們很難用肉眼去觀察的。此等纖維的微觀結構特性雖可以利用CAE模擬分析進行推估預測，但其正確性如何驗證，一直是產學界面臨之挑戰。為此，本研究主要利用微電腦斷層掃描及影像處理分析技術針對含有三個不同進澆流場之長平板複合材料之產品進行纖維微結構特性之探索，其中先針對應用相同配方之短纖維複合材料在不同進澆流場設計引發機械強度差異之原因探討部份，結果顯示Model I (側邊單點進澆)的機械強度大於Model II(直接單點進澆)，主要是因不同進澆流場設計引導長平板系統內在纖維排向差異所致，此等纖維排向差異可由CAE模擬分析推估，並且由微電腦斷層掃描及影像處理分析技術加以證明。其他纖維長度及纖維濃度分佈之微結構特性並非引發機械強度差異之主因。另外，針對不同纖維長度複合材料引發機械強度差異之原因探討部份，結果顯示從短纖維至長纖維配方變化，針對同一標準試片系統，產品之機械強度會隨纖維長度變化而增強，該強度增強之原因是來自於成品內保存之纖維長度增強所致。此部份可透過CAE模擬分析預測，並且透過微電腦斷層掃描及影像處理分析技術驗證。

In recent years, due to too fast growth of the human population, the pollution made by human has seriously impacts on our environment, particularly, for the CO2 emission. To diminish the CO2 emission problem, one of the effective solutions is applying lightweight material, such as the fiber-reinforced plastics (FRP), replacing plastics with plastics in automobile manufacturing is one of the effective ways to reduce emissions. However, since the reinforced function of the fibers inside plastic matrix is very complex, it is not easy to be visualized and managed. Although CAE simulation has been applied to analyze those micro-structure features, how to verify the CAE results is still challenge. To overcome this chellenge, in this study, we have studied the microstructure based on a system with three standard specimens based on ASTM D638 with different gate designs. Specifically, we have utilized micro-computed tomography (-CT) to take images of the inner structure and then utilized image analysis technology (Avizo) to analyze the micro features. Results showed that the tensile modulus and the strength of the Model I are greater than that of Model II. The reason why the tensile modulus and the strength of the Model I is greater than that of Model II is due to some entrance effect. That entrance effect will further provide flow-induced fiber orientation to melt and then enhance the tensile properties of Model I. Those fiber orientation features could be estimated using CAE analysis and further verified by -CT and image analysis technology.  Moreover, the fiber length and fiber concentration distribution obtained by CAE simulation could be verified by utilizing -CT and image analysis technology although these two factors are not the main reason to cause the tensile property difference between Model I and II.  Furthermore, for the tensile results of different fiber length reinforced materials, the tensile strength of the long fiber is greater than the strength of the short fiber.  The main contribution of the enhanced tensile strength is coming from the fiber length inside the injected parts.  Those detiled fiber length features inside the injected parts were measured using CAE simulation and verified by -CT and image analysis technology.

目錄	I
圖目錄	IV
表目錄	IX
第一章 緒論	1
1.1前言	1
1.2文獻回顧	2
1.3研究動機與目的	10
1.4論文架構	11
第二章 射出成型基本概念	13
2.1塑膠射出成型原理	13
2.2高分子材料介紹	17
2.2.1聚丙烯(Polypropylene)	19
2.2.2纖維強化塑膠	19
2.3纖維能提供強化結構之機理介紹	22
2.3.1纖維排向	22
2.3.2纖維長度	23
2.3.3纖維濃度	24
第三章 斷層掃描與影像處理技術介紹	25
3.1微電腦斷層掃描(Micro-CT)機台與技術介紹	25
3.3.1微電腦斷層掃描技術原理	25
3.2影像解析軟體與技術介紹	29
第四章 研究方法與流程	35
4.1研究方法與流程	35
4.2 CAE模擬分析系統與相關資訊	36
4.2.1 CAE模擬分析之基本理論	36
4.2.2模擬分析系統與相關資訊說明	42
4.2.3網格模型建立	44
4.2.4材料選擇	48
4.2.5操作條件設定	49
4.2.6 CAE模擬分析之硬體介紹	50
4.2.7 CAE模擬分析之軟體介紹	50
4.3實驗研究之系統與相關資訊	51
4.3.1 CLF-180TXL射出成型機台	51
4.3.2實驗操作條件設定	53
4.3.3模具系統介紹	53
4.3.4冷卻系統介紹	54
4.4產品特性分析相關儀器及背景說明	55
4.4.1萬能拉力機	55
4.4.2高溫燒結爐	58
4.5 影像處理分析方法與技術說明	62
4.5.1 微電腦斷層掃描技術拍攝之微結構影像說明	62
4.5.2 微電腦斷層掃描拍攝之影像匯入方法	63
4.5.3影像處理分析纖維追蹤學理	65
4.5.4纖維追蹤之參數設定	66
4.5.5影像解析纖維排向之分析	71
4.5.6影像解析纖維之長度分析	73
4.5.7影像解析纖維之濃度分析	75
4.6影像處理分析結果之驗證	76
4.6.1應用文獻公式進行纖維排向之驗證	76
4.6.2 應用Image J圖像技術進行纖維排向之驗證	80
第五章 結果與討論	83
5.1 不同進澆流場設計對射出成品拉伸強度之探討	83
5.1.1 射出成品拉伸強度之結果探討	83
5.1.2 短纖維複合材料成品之纖維排向CAE模擬分析結果	85
5.1.3 短纖維複合材料成品之纖維排向Avizo分析結果	88
5.1.4 短纖維複合材料成品之纖維長度CAE模擬分析結果	91
5.1.5 短纖維複合材料成品之纖維長度Avizo分析結果	93
5.1.6 短纖維複合材料成品之纖維長度燒結實驗結果	98
5.1.7 短纖維複合材料成品之纖維濃度CAE模擬分析結果	98
5.1.8 短纖維複合材料成品之纖維濃度Avizo分析結果	99
5.1.9 短纖維複合材料成品之纖維濃度燒結實驗分析結果	100
5.2 不同纖維長度對拉伸強度之探討	101
5.2.1 射出成品拉伸強度之結果探討	101
5.2.2 長纖維複合材料成品之纖維排向Avizo分析結果	103
5.2.3 長纖維複合材料成品之纖維長度Avizo分析結果	106
5.2.4 長纖維複合材料成品之纖維長度燒結實驗分析結果	110
5.2.5 長纖維複合材料成品之纖維濃度Avizo分析結果	112
5.2.6 長纖維複合材料成品之纖維濃度燒結實驗分析結果	114
第六章 結論	116
第七章 未來研究方向	118
第八章 參考文獻	119
第九章 作者簡歷	125

 
圖目錄
圖1-1 世界各國對於汽車的廢氣排放量標準	2
圖1-2 熔膠在模穴中噴泉流動行為	3
圖1-3 噴泉效應圖	3
圖1-4 偶數張量表示纖維分佈圖	4
圖1-5 定量分析短纖維複合材料之微觀結構	6
圖1-6 模擬纖維排向之五層結構位置	7
圖1-7 將µCT圖像分解成多個有限的體積	8
圖1-8 厚度方向之纖維排向圖	9
圖2-1-1 完整射出成型週期	14
圖2-1-2 完整射出成型週期(續)	15
圖2-2 熱塑性高分子結構	18
圖2-3 熱固性高分子結構	18
圖2-4 聚丙烯結構	19
圖2-5 纖維強化塑膠	21
圖2-6 纖維排向模擬圖	23
圖2-7 纖維長度對機械性質之影響	24
圖3-1 Micro-CT的原理	26
圖3-2 Bruker SkyScan 2211 微電腦斷層掃描機台	27
圖3-3 Bruker SkyScan 2211內部設置	27
圖3-4 Bruker SkyScan 2211微電腦斷層掃描機台與一般機台之差別	28
圖3-5 Ortho Slice功能顯示	30
圖3-6 Volume Rendering功能顯示	30
圖3-7 Extract Subvolume功能顯示	31
圖3-8 Convert Geometry To Label功能顯示	32
圖3-9 Dilation功能	32
圖3-10 Label Analysis功能選擇	32
圖3-11 Label Analysis數據呈現	33
圖3-12 Sieve Analysis纖維體積分類功能	33
圖3-13 Sieve Analysis纖維長度分類功能	34
圖3-14 Sieve Analysis纖維排向分類功能	34
圖4-1 研究流程	35
圖4-2 單根纖維向量圖	39
圖4-3 長平板系統	43
圖4-4 拉伸試片位置說明	43
圖4-5 冷卻水路配置	44
圖4-6 整體配置圖	44
圖4-7 網格類型種類	45
圖4-8 不同網格尺寸之進澆口壓力曲線圖	47
圖4-9 模穴系統網格品質圖	48
圖4-10 射出成型機 CLF-180TXL	52
圖4-11機台平面組立圖	52
圖4-12 CLF-180TXL機台模具	54
圖4-13 公模仁(左圖)及母模仁(右圖)	54
圖4-14 冷卻系統水路配置	55
圖4-15 萬能拉力機	56
圖4-16 拉伸試片標示代號	56
圖4-17 Stress-strain curve作圖	58
圖4-18高溫燒結爐	59
圖4-19 測量含纖維拉伸試片之重量	60
圖4-20 量測純纖維之重量	60
圖4-21量測纖維長度之方法	61
圖4-22 試片斷層掃描位置說明	62
圖4-23圖檔解析度設定	64
圖4-24 圖檔各方向之呈現	64
圖4-25 纖維追蹤之原理	65
圖4-26 纖維追蹤之狀況	65
圖4-27 纖維追蹤之參數設定	67
圖4-28 Minimum Seed Correlation參數比較	67
圖4-29 Minimum Continuation Quality參數比較	68
圖4-30 短纖維纖維長度追蹤比較圖	69
圖4-31 纖維追蹤圖結果(紅色參數)	70
圖4-32 纖維追蹤狀況	70
圖4-33 Line Probe功能	72
圖4-34 解析軟體之纖維排向分析	72
圖4-35 Excel纖維排向作圖	72
圖4-36 纖維長度數據圖	73
圖4-37 纖維長度分佈圖	74
圖4-38 Spatial Graph Filter	74
圖4-39 Spatial Graph Filter功能比較	74
圖4-40 Interactive Thresholding參數設定	75
圖4-41 濃度分佈之呈現	76
圖4-42 纖維向量圖	77
圖4-44 擷取之纖維排向圖層	81
圖4-45 纖維二值化過程	82
圖4-46 PAT-GEOM套件之計算纖維角度功能	82
圖5-1 短纖維拉伸之應力應變曲線	84
圖5-2 純PP與短纖維之拉伸強度結果	85
圖5-3 短纖維Model I NGR模擬纖維排向之結果	87
圖5-4 短纖維Model II NGR模擬纖維排向之結果	87
圖5-5 短纖維Model I CR模擬纖維排向之結果	87
圖5-6 短纖維Model II CR模擬纖維排向之結果	88
圖5-7 短纖維Model I EFR模擬纖維排向之結果	88
圖5-8 短纖維Model II EFR模擬纖維排向之結果	88
圖5-9 短纖維Model I NGR Avizo纖維排向之結果	90
圖5-10 短纖維Model I CR Avizo纖維排向之結果	90
圖5-11 短纖維Model I EFR Avizo纖維排向之結果	90
圖5-12 短纖維Model II NGR Avizo纖維排向之結果	91
圖5-13 短纖維Model II CR Avizo纖維排向之結果	91
圖5-14 短纖維Model II EFR Avizo纖維排向之結果	91
圖5-15 CAE模擬分析之短纖維Model I平均纖維長度	92
圖5-16 CAE模擬分析之短纖維Model II平均纖維長度	93
圖5-17 CAE模擬分析之短纖維Model I與Model II平均纖維長度比較	93
圖5-18 短纖維Model I NGR纖維長度分佈圖	95
圖5-19 短纖維Model I CR纖維長度分佈圖	95
圖5-20 短纖維Model I EFR纖維長度分佈圖	96
圖5-21 短纖維Model II NGR纖維長度分佈圖	96
圖5-22 短纖維Model II CR纖維長度分佈圖	96
圖5-23 短纖維Model II EFR纖維長度分佈圖	97
圖5-24 Avizo分析之短纖維Model I與Model II平均纖維長度比較	97
圖5-25 短纖維Model I與Model II燒結實驗的纖維長度測量結果	98
圖5-26 短纖維CAE模擬之濃度分析結果	99
圖5-27 短纖維Avizo解析之濃度分析結果	100
圖5-28 短纖維Model I與Model II的纖維含量比較	100
圖5-29 短纖維與長纖維拉伸之應力應變曲線	102
圖5-30 不同進澆流場與不同材料之拉伸強度結果	102
圖5-31 長纖維Model I NGR Avizo纖維排向之結果	104
圖5-32 長纖維Model I CR Avizo纖維排向之結果	104
圖5-33 長纖維Model I EFR Avizo纖維排向之結果	105
圖5-34 長纖維Model II NGR Avizo纖維排向之結果	105
圖5-35 長纖維Model II CR Avizo纖維排向之結果	105
圖5-36 長纖維Model II EFR Avizo纖維排向之結果	105
圖5-37 長纖維Model I NGR纖維長度分佈圖	107
圖5-38 長纖維Model I CR纖維長度分佈圖	107
圖5-39 長纖維Model I EFR纖維長度分佈圖	108
圖5-40 長纖維Model II NGR纖維長度分佈圖	108
圖5-41 長纖維Model II CR纖維長度分佈圖	109
圖5-42 長纖維Model II EFR纖維長度分佈圖	109
圖5-43 Avizo Model I長纖維與短纖維平均纖維長度比較	110
圖5-44 Avizo Model II長纖維與短纖維平均纖維長度比較	110
圖5-45 長纖維Model I與Model II燒結實驗量測結果	111
圖5-46 Model I長纖維與短纖維之燒結實驗比較	112
圖5-47 Model II長纖維與短纖維之燒結實驗比較	112
圖5-48 Avizo長纖維Model I與Model II纖維含量分佈結果	113
圖5-49 Avizo Model I短纖維與長纖維濃度分佈比較	113
圖5-50 Avizo Model II短纖維與長纖維濃度分佈比較	114
圖5-51 長纖維Model I與Model II燒結實驗之纖維含量	114
圖5-52 短纖維Model I與Model II燒結實驗之纖維含量	115
表目錄
表4-1 不同網格尺寸進行模擬分析相關資訊	46
表4-2 本研究模擬分析專案使用之網格相關資訊	47
表4-3 材料型號及製造商	49
表4-4 原始設計之加工參數	49
表4-5射出成型機規格	52
表4-6 實驗參數設定	53
表4-7 拉伸試片規格	57
表4-8 掃描檔案規格說明	63
表4-9 纖維追蹤參數比較表	69
表4-10 Cylinder Correlation與Trace Correlation Line參數設定	70
表4-11 纖維追蹤之公式換算	77
表4-12 影像處理軟體內部所得之排向角度θ及ψ的數據	78
表4-13 利用排向角度θ及ψ進行各個排向張量之計算	78
表4-14 Avizo影像處理軟體之張量結果與公式計算之張量結果比較	79
表4-15 Avizo與Image J 纖維排向結果之比較	82
表5-1 短纖維拉伸數據整理	85
表5-2 短纖維與長纖維拉伸數據整理	102

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