隨著加工技術的水準不斷提升，產品設計也越來越複雜，而複雜零件常使用五軸加工中心機進行銑削，在五軸同動的情況下加工，會因為機台本身的軸向穩定度較差，造成加工後的零件組裝精度不佳。本研究針對運動型安全帽的射出成型模具，提出一套以3+2軸加工之流程，來克服五軸同動加工穩定度的問題，首先在Creo 3.0的3D CAD環境下，配合可視性分析進行模具設計；接著以所設計的模具分析加工軸的方向，讓零件在加工時旋轉至特定的軸向，以三軸工法進行切削加工，增加加工的穩定度；最後將模具進行實體切削模擬，模擬結果顯示本研究的所設計的3+2軸加工流程，能夠完整切削出模具，並且無殘料及過切現象，印證本論文所提方法的可行性。

As the level of machining techniques continues to rise, product design is becoming increasingly complex. In addition, complex parts often undergo milling in a 5-axis machining, but are susceptible to poor precision after machining due to lower axial directional stability in the machine itself during machining in 5-axis synchronous motion. In this study, a 3+2-axis machining process was proposed for sports helmet injection molding molds to solve the problem in machining stability caused by 5-axis synchronous motion. First, a mold was designed in the 3D CAD environment of Creo 3.0 in combination with visibility analysis. Then, an analysis was run based on the designed mold to determine the direction of machining axes so that the part could rotate in the specified axial direction during machining. Cutting of the mold was done using a 3-axis method to increase the machining stability. Finally, the mold underwent solid cutting simulation. The simulation results showed the 3+2-axis machining process designed in this study could cut out a complete mold without any residue and overcut. This proves the viability of the proposed method in this paper.

[1]Effendi, M. K. (2016), “Finding Pull Directions for Interference-free Mold Openings,＂International Conference on Design, Mechanical and Material Engineering, September 8-10, 2016, Auckland, New Zealand.
[2]Fu, M. W., Fuh, J.Y.H. and Nee, A.Y.C. (1999), “Generation of optimal parting direction based on undercut features in injection molded parts,＂IIE Transactions, Vol. 31,No. 10, pp.947-955.
[3]江嘉仁，「塑膠零件之CAD模型脫模性分析」(2004)，碩士論文，國立成功大學機械工程研究所，台南市。
[4]高國智，「薄殼物件的脫模性研究」(2001)，碩士論文，國立臺灣大學機械工程學研究所，台北市。
[5]Chen, Y.H. (1997), “Determining parting direction based on minimum bounding box and fuzzy logics,＂International Journal of Machine Tools and Manufacture, Vol 37, No. 9, pp. 1189-1199.
[6]Ye, X.G., Fuh, H. and Lee, K.S. (2004), “Automatic undercut feature recognition for side core design of injection molds.＂International Journal of Mechanical Design, Vol 126, pp. 519-526.
[7]葉家哲，「使用Creo進行運動型頭盔之模具元件設計」(2014)，碩士論文，國立臺灣科技大學機械工程研究所，台北市。
[8]朱麗鴛，「電腦輔助射出成型製品分模線自動產生方法之研究」(1995)，碩士論文，國立臺灣工業技術學院工程研究所，台北市。
[9]Fu, M. W., Nee, A.Y.C. and Fuh, J.Y.H., (2002),“The application of surface visibility and moldability to parting line generation,＂Computer-Aided Design, Vol. 34,No. 6, pp. 469-480.
[10]林德聰、林清安，「運用支撐腳進行塑膠件快速打樣」(2009)，中國機械工程學會第二十六屆全國學術研討會論文集，成功大學。
[11]黃文彥，｢五軸零件加工之支撐腳設計｣(2015)，碩士論文，國立臺灣科技大學機械工程研究所，台北市。
[12]林子寬，「鞋楦精加工4軸NC程式產生」(2004)，碩士論文，國立臺灣科技大學機械工程研究所，台北市。
[13]韋經智，「應用可視性理論於五軸加工之夾持高度與刀軸角度最佳化」(2014)，碩士論文，國立臺灣科技大學機械工程研究所，台北市。
[14]Woo, C. Tony, and von Turkovich, B.F. (1990),“Visibility map and its application to numerical control,＂Annals of the CIRP, Vol 39, pp. 451-454.
[15]Morishige, K., Kase, K. and Takeuchi, Y., (1997),“Collision free tool path generation using 2-dimensional C-space for 5-axis control machining,＂International Journal of Advanced Manufacturing Technology, Vol. 13, pp. 393-400.
[16]張凱翔，｢曲面零件加工之定位點與夾持點搜尋法則｣(2016)，碩士論文，國立臺灣科技大學機械工程研究所，台北市。
[17]http://www.jamsong.com.tw/index.php?tpl=prod&cid=97