塑膠射出成型是大量生產塑膠製品的關鍵技術，該技術有兩個重要議題：決定適當的脫模方向及決定適當的模具加工方向。
一個自由曲面有無限個法線方向，因此要決定自由曲面的脫模方向有相當高的困難度，常用的解決方式是將一個自由曲面轉換為多個平面，以限制法線方向的個數，但此法降低了計算精密度，因此本研究的第一個目的是針對含有多個自由曲面的複雜零件，提出如何決定高精度脫模方向的方法。首先使用「均勻分布修正法」來求出原始的脫模方向，而法線方向則是由取點方塊來求出，脫模方向及法線方向的個數皆以數值方式來求取其優化值；接著以Barycentric修正法過濾原始的法線方向，以提昇計算速度，然後再使用分層過濾V-map的方式，由原始的脫模方向挑選出合適的脫模方向；最後再用本研究所提的分類演算法求出最少數量的模仁及滑塊。
脫模方向的決定可藉以進行模具設計，由於複雜產品的模具可能含有數個模具零件，而零件的接合部位常為曲面，因此需要高精度的加工品質。在五軸加工機上使用3+2軸的加工策略是公認提高加工精度的好方法，因此本論文的第二個研究目的是針對含有多個自由曲面的複雜模具零件進行3+2軸加工時，如何減少模具的加工方向。首先使用分層過濾V-map的方法來產生可能的加工方向，接著使用遺傳演算法找出加工方向的啟始值，最後提出避免阻擋及凝聚的方法來決定合適的加工方向。
本論文使用數個日常生活可見的複雜零件來驗證所提方法的正確性與可行性，首先建立這些零件的3D CAD模型，然後以所提的方法求出脫模方向及加工方向，結果顯示這些脫模方向都不會造成零件和模具之間的干涉，且模具零件皆能以少數的加工方向來進行切削。最後，本研究使用五軸加工機進行模具零件的真實加工。

Injection molding is one of the most prominent techniques for its capability to mass-produce complex parts in one single-stage operation, especially for plastic products. However, there are two challenging problems in conducting plastic injection molding, namely determining appropriate pull directions for mold opening and determining appropriate machining directions for mold components.
The determination of pull directions for a freeform surface is challenging because of the unlimited number of normal vectors. Thus, researchers generally convert a freeform surface into planar faces to limit the number of the normal vectors, but this resulted in the converted surfaces to reduce the accuracy of the pull directions. In this regard, the first objective of this research study is to determine highly accurate pull directions for a complex part with multiple freeform surfaces. The pull direction options are firstly generated using a modified regular-placement method, and the normal vectors are then extracted by a sampling box. The number of the pull direction options and normal vectors are optimized through a numerical approach. Next, significant normal vectors are selected using a modified Barycentric method to reduce the processing time. A cascade filter of the V-map is then used for selecting the feasible pull directions. Subsequently, a minimum number of sliders and cavities in molding is finally obtained using a proposed clustering algorithm.
The finding on pull directions is subsequently used to design mold components. The molding of a complex part is normally composed of several mold components and the mating surfaces among components are mostly complex geometry which requires high quality of machining surfaces. The use of 3+2 axis setup in a five-axis machine is a typical way to increase the geometric accuracy. Therefore, the second objective of this research study is to reduce the number of machining directions for a complex mold component with multiple freeform surfaces, using the strategy of 3+2 axis setup. Firstly, the method of cascade filter of V-maps are again used for selecting the feasible machining directions. Afterwards, a genetic algorithm is used for determining the appropriate initial machining directions. Moreover, a blockage solver and an agglomeration method are applied in sequence to update the machining directions.
In order to evaluate the performance of the proposed method, the 3D CAD models of complex real-life products are generated and used in the implementation phase. The proposed method is used to find the pull directions, and the computational results showed no interferences between the products’ CAD models and the molds during the mold opening stage. The computational results also showed that the mold’s CAD model could be machined using the minimum number of machining directions. Then, a 5-axis NC machine is used to produce the final mold components.

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