천정형 에어컨 부품의 초미세발포 사출성형 특성 규명

Abstract

In this study, microcellular injection molding is applied to reduce warpage on the four-way air inlet grille of ceiling air conditioner. Significant difference in product weight and warpage is identified by using 2-sample T and ANOVA method and increasing mixing rate of gas and resin was effective. According to the high ratio of chemical form, the viscosity of the resin was decreased. As a result, injection conditions such as injection pressure, clamping force and warpage were improved. It does not affect the warpage temperature and injection speed. However, it reduces product weight due to high ratio of forming rate. In addition, it is helpful for the uniform temperature of the product. When the width of the rib is increased, the warpage is decreased. However, at the specific width, the width increase and the increase in the warpage. Also, at the CAE result, the amount of warpage is higher than real data, but the tendency was the same. Therefore, the relative comparison, prediction of the amount of warpage and minimization is possible. In addition, by different type of chemical foam, different weight was evaluated. For the optimization of process conditions, six sigma and response surface method is used which is useful for the optimum solution. As a result, the average weight is reduced from 1,751.4g to 1425g (18.6%). Deviation is reduced from 1.49 g to 1.13 g (24.2%). Finally, process capability is increased from negative 219.75 to 26.01. Also, for the warpage, the average warpage was reduced from 1.96mm to 0.55mm (71.9%) and Deviation was from 0.46mm to 0.19 (58.7%). Process capability of warpage was increased from 2.2 to 14.5. As a result, 15 percent of production cost is reduced. From this study, it was found to be an effective solution to the minimum weight and warpage by statistical method such as six sigma and response surface method and so on. It is verified that consideration of factors can get the good product quality as well.