本研究目標為將「彈性3D成形技術」(FAM)中的基本表面製程步驟自動化，並與佈料程序整合，以便輸出電腦模型並直接製造出一個3D物件。表面製程步驟的特徵在於熱刮，乃以加熱後的刮棒沿著列印表面進行表面刮平，並與佈料程序連續切換來得到光滑的物體表面。本研究以一個葉輪的部分模型為測試案例，使用ABS作為測試材料，發展熱刮程序如垂直牆、直立的3D表面以及水平表面等典型3D幾何形狀的自動化表面製程步驟，並且製作出用於切換熱刮頭和佈料頭的旋轉機構，以利於交替佈料程序和熱刮程序。實驗上熱刮程序的軌跡與佈料的軌跡相同，但深度資訊、速度資訊、重複次數、去毛邊步驟、工具形狀和溫度控制都會影響表面精度。這些結果將有助於未來在「彈性3D成形技術」(FAM)的佈料和熱刮的自動化發展。

This research develops basic process steps of a surface processing procedure that is to be automated and integrated with the forming process of the Freeform Additive Manufacturing (FAM) to make a 3D object with smooth surfaces directly from a computer model. The surface processing procedure features a hot scraping process that is applied over surfaces of a portion of the 3D object after material dispensing of that portion; and successive steps of material dispensing followed by surface scraping complete an object with smooth surfaces. This research tested and developed automated process steps of hot scraping of typical 3D geometries including vertical wall, erected curved 3D surface and horizontal surface using a partial model of an impeller as test case and ABS as test material. A rotary mechanism for switching between dispensing head and hot scraping head was made to facilitate the alternating dispensing-scraping steps. Trajectories of the hot scraping process steps are basically based on trajectories of material dispensing; but detailed scraping parameters such as depth, feed, speed, number of repeated passes, deburring steps, tool shape and temperature were determined by experiments. The results will be useful for full automation of the dispensing-scraping steps of the FAM process in the future.

摘要 I
Abstract II
目錄 IV
圖目錄 VIII
表目錄 XV
第一章 緒論 1
1.1 動機與目的 1
1.2 技術回顧 6
1.2.1 佈料程序改善表面品質 6
1.2.2 化學方式改善表面品質 8
1.2.3 物理方式改善表面品質 10
1.3 研究方法 13
第二章 熱刮系統設計 14
2.1 本實驗室過去的熱刮實驗 14
2.2 熱刮機構概念設計 17
第三章 熱刮製程與參數實驗 19
3.1直立式模型熱刮-輪毂 19
3.1.1 輪毂熱刮基礎參數 19
3.1.2 輪毂熱刮路徑 20
3.1.3 輪毂分層熱刮步驟 20
3.1.4 輪毂分段進給熱刮 21
3.1.5 輪毂去裙 23
3.1.6 輪毂熱刮總流程 25
3.2 直立式3D表面模型熱刮-葉片 28
3.2.1 葉片熱刮基本參數 28
3.2.2 葉片熱刮路徑 29
3.2.3 葉片分層熱刮步驟 30
3.2.4 葉片去裙 31
3.2.5 葉片熱刮總流程 36
3.3水平式模型熱刮-底板 39
3.3.1底板熱刮基本參數 39
3.3.2 底板熱刮路徑 40
3.3.3 底板熱刮步驟 41
3.3.3 底板精刮 44
3.3.4底板熱刮總流程 47
3.3.4 次數、角度和速度實驗 49
3.4 實驗上的其他觀察與發現 53
3.5 全模型實驗 56
3.5.1 全模型組合列印 56
3.5.2 全模型組合熱刮 57
第四章 結論 62
參考文獻 65
附錄 68
附錄一 佈料程序參數規畫 68
1.1 速度及溫度的測試 68
1.2 預進料 70
1.3 起步固定 72
1.4 內部佈料路徑 73
1.5 佈料成形冷卻 77
附錄二 佈料系統與五軸運動系統的整合 78
2.1 佈料系統的基本架設 78
2.2 佈料系統與五軸CNC的整合 80
2.3 五軸速度控制與控制辦法 81
附錄三 表面粗糙度介紹 85

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