本研究的目的是開發「彈性3D成形技術」製作精密鑄造用蠟型的佈料系統以及相關的製程。「彈性3D成形技術」是新開發的基層製造技術，特點為沿3D物件表面的切線方向佈料成形，並且根據物件表面曲度變更佈料成形方向及寬度，藉以提升成形速度；另外，在製程中加入熱刮製程將成品的表面抹平，以熱刮製程提升成品表面粗糙度。本研究將對工業用蠟進行可行性實驗，以列印葉輪部分模型為目標，找出適合的列印速度、佈料速度、佈料頭溫度，根據參數開發新的佈料系統，包含新的進料機構、佈料頭，兼具水平及垂直的佈料方向的自動切換並包含3DP技術中可變寬的功能，並開發葉片疊層參數以及冷卻降溫；最後結合熱刮機構及切換機構，結合列印製程與熱刮表面製程完成原型機，實現工業用蠟的「彈性3D成形技術」列印精密鑄造用之蠟型。

This research aims to develop a set of material dispensing system and process that meets the requirement of manufacturing industrial wax pattern for investment casting wax by applying “Freeform Additive Manufacturing (FAM)’’. The major features of the FAM technology are vari-directional material deposition along the tangential directions of part surface which gives surface smoothness and vari-dimensional material deposition according to the need of local geometry to increase build rate. A hot scraping process is added to smooth the surface of the product to improve surface finish. Separate tests were first conducted to form ribbon-shaped wax deposits, experiment basic process operations and determine basic process parameters such as dispensing speed, material feed rate and dispensing head temperature. From these results, a prototype material dispensing systems including a new feeding mechanism, a dispensing head combining horizontal and erect dispensing capability and a mechanism for adjusting widths of exits were design and build. Additional process parameters such as dispensing speed control, ribbon to ribbon joining technique and cooling arrangement were experimented and determined. Using the prototype system together with a hot scraping system, a wax pattern of a section of an impeller model were built by successive, alternating dispensing and hot scrapping operations on a single machine, demonstrating the functions of the new dispensing head and the FAM building process for wax patterns.

摘要 i
目錄 iii
圖目錄 v
表目錄 x
第一章 緒論 1
1.1研究動機與目的 1
1.2彈性3D成形技術 3
1.3技術回顧 7
1.4研究方法 21
第二章 蠟成形實驗 23
2.1簡易佈料頭測試 23
2.2進料機構製作 25
2.3佈料方向與成形方向測試 27
2.4熱刮製程可行性實驗 28
第三章 機構設計 30
3.1佈料頭設計 30
3.1.1佈料頭功能設定 30
3.1.2料腔與閘門設計 33
3.1.3傳動機構與控制設定 38
3.1.4列印測試 40
3.2熱刮機構 47
3.3切換機構 48
3.4整體機台架構與操作 50
第四章 成形製程開發與實驗 52
4.1列印製程驗證 52
4.2 熱刮製程驗證 63
4.3葉輪模型列印 69
第五章 結論 80
5.1未來工作 82
5.2展望 83
附錄 84
A. 彈性 3D成形曲面熱刮棒 84
B.進料機構Arduino控制碼 94
C. 實驗用材料 98
D. 研究用相關軟體與列印用G-code 99
E. 佈料頭CAD檔案及零件表 100
參考文獻 104

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