| 摘要: | 塑膠正齒輪(Plastic Spur Gear)因具備優異的機械性能、耐磨耗性、減振能力與耐化學性，廣泛應用於機械運作流程及各類輕量化機械設備中。作為機械傳動系統中的關鍵元件，塑膠齒輪需具備高度精度，以確保傳動效率與穩定性。傳統上，塑膠齒輪多以射出成形製程製造，當產品需具特殊規格時，模具開發所帶來的高成本與製程限制，常使製造流程變得困難。
光固化技術(Stereolithography Apparatus, SLA)是一種利用光聚合反應選擇性固化光敏樹脂，逐層堆疊以製作三維模型的成型方式。隨著技術演進，光固化技術已由早期成本高昂的系統，發展至較為經濟實用的液晶顯示光固化成型技術。本研究採用具備8K解析度之液晶顯示光固化成型設備，進行工程塑膠正齒輪之製作，旨在探討此成型技術是否具備滿足製造業實際應用需求之可行性。
本研究以市售MISUMI齒輪(型號：GEABP2.0-15-20-A-12)作為參考基準，透過三次元量測儀進行齒輪幾何精度評估，並依據日本工業規格(JIS B 1702-1與B 1702-2)進行精度等級判定，以驗證本研究之量測流程之準確性，旨在探索使用8K解析度光固化技術製造工程塑膠正齒輪在JIS精度規範上的實際表現與潛在挑戰。其次，透過田口方法設計實驗並分析不同SLA列印參數對節距誤差、齒形誤差與齒線誤差之影響，嘗試尋求優化列印條件，並評估其在提升齒輪精度方面的有效性。
實驗結果顯示，在田口方法望小特性分析下，各項精度指標的數據呈現顯著的波動，未能確立一致且穩定的製程模型以達成JIS精度目標，由於實驗數據的高度不穩定性，列印出的正齒輪的精度等級普遍落於 JIS N10 至 JIS N12 等級範圍內。田口方法分析表明，儘管嘗試了不同參數組合，光固化列印所製得的正齒輪在精度表現上未呈現穩定趨勢，且與市售參考齒輪(JIS N9等級) 之間存在顯著差距。這說明在當前實驗條件與規劃下，光固化技術在製造高精度齒輪方面仍存在顯著限制。
;Plastic spur gears possess excellent mechanical properties, wear resistance, vibration damping, and chemical resistance, making them widely adopted in various mechanical operations and lightweight equipment. As vital components in mechanical transmission systems, high precision in plastic gears is crucial for ensuring efficient and stable power transfer. Traditionally, plastic gears are produced via injection molding. However, manufacturing parts with unique specifications often entails high mold development costs and significant process limitations, making production challenging.
Stereolithography Apparatus (SLA) is an additive manufacturing method that builds three-dimensional models layer by layer through the selective solidification of photosensitive resin via photopolymerization. With technological advancements, SLA has evolved from its early, high-cost systems to more economical and practical LCD-based SLA technology. This study utilized an 8K resolution LCD-based SLA system for producing engineering plastic spur gears, aiming to investigate the feasibility of this additive manufacturing technology in meeting the precision demands of industrial applications.
This research used a commercially available MISUMI gear (model: GEABP2.0-15-20-A-12) as a reference. Gear geometric precision was evaluated using a coordinate measuring machine (CMM), and precision grades were determined according to Japanese Industrial Standards (JIS B 1702-1 and B 1702-2) to validate the accuracy of our measurement procedure. The primary goal was to explore the actual performance and inherent challenges of manufacturing engineering plastic spur gears using 8K resolution SLA technology within the context of JIS precision standards. Furthermore, the Taguchi method was employed for experimental design to analyze the influence of various SLA printing parameters (such as exposure time, lift speed, layer thickness, and printing angle) on pitch error, tooth profile error, and total lead error, attempting to identify optimized printing conditions and evaluate their effectiveness in improving gear precision.
The experimental results show that under the "smaller-the-better" characteristic analysis of the Taguchi method, the data for various precision indicators exhibited significant fluctuations, failing to establish a consistent and stable process model to achieve the JIS precision targets. Due to the high instability of the experimental data, the precision grades of the printed spur gears generally fell within the JIS N10 to JIS N12 range. The Taguchi method analysis indicates that despite attempts with different parameter combinations, the spur gears produced by SLA printing did not show a stable trend in precision performance and there was a significant gap compared to the commercially available reference gear (JIS N9 grade). This suggests that under the current experimental conditions and planning, SLA technology still has significant limitations in manufacturing high-precision gears. |
