快速原型(Rapid Prototyping,RP)加工，不論是何種材料或建構方法，懸臂工件的翹曲變形總是難以克服，其中造成RP懸臂樑工件的撓度之可能原因為RP材料的重量、冷卻期間的熱應力、及拉拔力等。本論文為了提高尺寸的精度及改善翹曲變形的問題而提出設計上的策略，以ANSYS有限元素軟體進行分析，主要以量測及結構分析的觀點，探討下照式面光源動態光罩快速原型機所製作之工件的翹曲情形。
基於力學分析的結果，RP 材料的重量所造成的撓度將可被忽略。實驗載具的設計以具有懸臂樑特徵的RP件為主，在考慮熱分佈與結構模式下，將工件切成數層以ANSYS軟體進行分析，得到工件一層之變形結果，再於變形層上疊上新的一層，最後可預估工件的翹曲變形情況。同時進行RP實體之製作及以三次元量測儀(CMM)量測，由誤差比對之結果可知，分析結果與量測結果之趨勢相吻合。
藉由ANSYS軟體對翹曲變形分析的結果 ，進一步提出“變截面樑”概念形式作為改進精度的策略，使翼延伸是隨高度的增加而逐漸延伸，避免使懸臂於初期建構時即承受過大的彎矩而導致變形，同時亦避免危險截面重覆出現在同一斷面上，造成工件之疲勞破壞。經改善後，在工件最大變形處，分析誤差百分比為5.18％，實驗誤差百分比為8.90％，比對結果顯示，說明本研究所提之改善策略可確實修正工件之變形情形，提高精工件精度。最後將分析的方法及策略應用於螺旋葉片的設計與製作，以CMM量測得到的輪廓精度之RESM(root mean square error)為0.1791mm。

Cantilever beam deflection of a RP part fabricated by the down-projected DLP-based rapid prototyping (RP) system is still a problem to be solved. Possible reasons, such as the weight of the RP material, thermal stress during cooling process, and the pulling force, can result in the cantilever beam deflection of a RP part. In order to propose to a design strategy to eliminate the deflection of a cantilever beam of a RP part, this study investigates the deflection analysis of a RP part created by the weight of the RP material, thermal stress during cooling process, and the pulling force with the help of a CAE software, ANSYS software.
The deflection formed by the weight of the RP material can basically be neglected based on the result of mechanics analysis. To analyze the deflection formed by the thermal stress and the pulling force, a RP workpiece CAD model with cantilever beam was designed and investigated layer by layer with the ANSYS software. To verify the reliability of the CAE analysis, the designed workpiece was fabricated as RP part and then measured with a coordinate measuring machine (CMM). The deformation analyzed by the ANSYS software is highly consistent with the deformation measured by the CMM.
According to the results of deflection analysis with the help of ANSYS software, a “variable-section beam” concept was proposed to eliminate the cantilever beam deflection and to avoid the happening of a dangerous section on a RP part. Using the proposed strategy and modifying the design of cantilever beam, the largest deflection error of the workpiece via CAE analysis was 5.18%, whereas that of the measured error was 8.90%. The simulation result shows the proposed strategy can eliminate the workpiece deflection and improve the workpiece profile accuracy. The proposed strategy is applied to the design and fabrication of a RP part of heat-dissipated fan. The root mean square error of the profile was about 0.1791mm based on the measurement result on a CMM.

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