臺灣博碩士論文加值系統

現今加減法複合式加工機多以指向性能量沉積(DED)或粉體熔化成型(PBF)去結合CNC銑削加工減法製造，如以DED搭配CNC銑削加工，將加法成形工件表面原來的粗糙，輔以切削，而達到高精度及平滑；而PBF搭配CNC銑削加工需要一支撐結構支撐懸垂特徵，其支撐結構處不可以被加工，以避免之後的懸垂特徵無法繼續建立。然而，DED與PBF這兩種複合加工都不適用於製作內表面光滑及軟質材料的鏤空工件。
本研究為改良陳[34]的「可用於薄殼鏤空工件的加減法製造系統」，除了具備加減複合系統技術基礎，主要目的著重於加法製造系統，製作出鏤空工件。其中包括了加熱熔融擠製機構設計與建製，編輯軟體設計、編織加工路徑設計以及鏤空結構的加減法製造實驗驗證。本系統設備目標將可以製作出100mm(直徑)×200mm(長度)之尺寸工件，將熱塑性彈硬材料以材料擠型技術來製作，使成品具有平滑內表面及物件具彈性等特徵，將可適用於與人體皮膚表面接觸及保持通風。

The hybrid manufacturing systems in the market are based on the Direct Energy Deposition (DED) and Powder Bed Fusion (PBF) additive manufacturing process, to integrate the CNC subtractive manufacturing process. For example, the DED and CNC hybrid system using DED to form the green shape and using CNC to milling the outer surface. The PBF and CNC hybrid system using PBF to from the green shape with strong support structure followed by the CNC to cut the outer surface of the green shape. These two hybrid systems are not able to manufacturing parts with smooth inner surface and with elasticity hollow structures.
The current project of “The development of subtractive and additive manufacturing for thin shell with hollow structure object” [34] proposes a new concept of the manufacturing process by changing the sequence of “additive first and subtractive later” to “subtractive first and additive later”. The progress of the above project has construct the concept machine, the CAD/CAM software, and is going to use solvent based TPU as the material to extrusion from a nozzle. Different from that project, the thermal plastic elastic material will be used and the thermal extrusion nozzle is going to be designed and used. Moreover, the designing software of the hollow structure object will be designed. And, the CAD/CAM system to generate the tooling path of the extrusion nozzle will be developed. The working volume of the new system is 100mm (diameter) x 200mm(length). The resulting parts are able to manufacturing parts with smooth inner surface and with elasticity hollow structures. The results of the system will bring the possibility to design and manufacture personal assistive device like kneepad brace.

摘要 i
ABSTRACT ii
誌謝 iv
目錄 v
表目錄 viii
圖目錄 ix
第一章 緒論 1
1.1 前言 1
1.2 研究背景 2
1.2.1 積層製造之背景 2
1.2.2 複合式製造之背景 3
1.3 研究目的 4
1.4 論文架構 5
第二章 文獻探討 6
2.1 國內外積層製造之相關探討 6
2.2 材料擠製積層製造之系統回顧 9
2.2.1 熔線擠製技術 9
2.2.2 氣壓式擠製技術 11
2.2.3 活塞式擠製技術 13
2.2.4 螺旋式擠製技術 15
2.3 複合式製造技術 18
2.3.1 SDM技術 18
2.3.2 加減複合系統探討 19
2.4 薄殼鏤空結構相關文獻 23
2.5 各成型系統之分析 26
第三章 加減法製造系統介紹 28
3.1 加減複合製程原理 28
3.2 加減複合製造設備 30
3.2.1 主軸端機構分析 31
3.2.1.1 刀具主軸 32
3.2.2 切削端機構分析 33
3.3 熔融擠製技術系統設計 35
3.3.1 加熱夾治具設計 36
3.3.2 加熱套設計 37
3.3.3 高溫陶瓷加熱片介紹 39
3.3.4 微阻礙馬達自轉設計 40
3.4 溫度控制系統 41
3.4.1 溫度控制器與溫度感測線 41
3.4.2 固態繼電器介紹 42
3.4.3 溫度控制系統組合 44
3.5 結論 45
第四章 加工控制與軟體技術 46
4.1 系統控制架構 46
4.1.1 加工控制設置 47
4.1.2 擠製軸控制分析 47
4.1.2.1 直線步進馬達介紹 48
4.1.2.2 擠製R軸之控制 49
4.1.2.3 擠製A軸之控制 51
4.2 軟體設置 52
4.2.1 切削參數分析 52
4.2.2 座標轉換 53
4.2.3 客製化輔具分析 54
4.2.4 切削路徑規劃 55
4.2.5 CAD/CAM軟體模擬 56
4.2.6 加工分析 57
4.2.7 程式轉換軟體分析 58
4.3 結論 62
第五章 複合式加工結果與討論 63
5.1 減法製造成型 63
5.1.1 切削材料介紹 63
5.1.2 切削加工分析 64
5.2 加法製造成型 68
5.2.1 擠製材料介紹 68
5.2.2 材料選用 69
5.2.3 成型實驗 70
5.3 活塞擠製排氣探討 73
5.4 鏤空結構工件之材料實驗 74
5.4.1 不同材料成品之拉伸試驗 74
5.4.2 不同密度薄厚成品之拉伸試驗 78
5.4.3 拉伸試驗討論 80
5.5 加工結果討論 82
第六章 結論與未來展望 84
6.1 結論 84
6.2 未來展望 85
參考文獻 86

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