基于蒸汽平滑工艺对FDM零件的表面粗糙度控制研究

熔融沉积成型技术（FDM）因其原材料利用率高、适合复杂模型的快速验证以及可以生产定制化的产品等优势为实体产品设计带来了创新的制造方法，加速了原型制作和设计验证的过程。然而，由于FDM自身固有缺陷导致的阶梯效应以及层纹现象使其加工的产品或零件表面光洁度较差、粗糙度分布不均，限制了其在实体产品设计领域的发挥，尤其是实体产品表面粗糙度的设计验证和快速迭代。为响应国家工程教育改革新要求，本研究通过多学科交叉，致力于探索如何助推FDM技术更好地为实体产品设计过程赋能。

基于此背景，本研究通过化学蒸汽平滑工艺对FDM零件样品进行处理，探究零件表面粗糙度的变化规律，以实现对FDM零件粗糙度的控制，为实体产品的粗糙度设计提供一种快速迭代工具。为了让蒸汽平滑的过程变得缓和可控，本研究按照不同的体积比混合丙酮和乙酸乙酯溶液，通过加热的方式对ABS零件进行蒸汽平滑，得到了不同构建角度零件的表面粗糙度随时间的变化情况，并分析了平滑过程中零件表面粗糙度的变化规律。依据实验结果，为不同构建角度的零件分别选择了合适的平滑试剂比例，并拟合出了相应的粗糙度—时间变化曲线，得到了对应的函数方程。最后，为了验证该曲线的准确性，本文通过在函数方程中代入预设的粗糙度数值来求解相应的处理时间，并测试了在该时间条件下零件的粗糙度与理论粗糙度的一致性。

结果表明，蒸汽平滑过程中零件的粗糙度—时间曲线的拟合优度均高于99%；在验证实验中，不同构建角度零件的表面粗糙度表现出了显著的一致性，与预设粗糙度的最大偏差控制在了1μm范围内。证实了曲线拟合结果的准确性、以及使用蒸汽平滑工艺控制FDM零件表面粗糙度的可行性。

The Fusion Deposition Modeling (FDM) technique has revolutionized manufacturing methods in physical product design, offering advantages such as high material utilization, rapid validation of complex models, and customization capabilities. However, inherent deficiencies like the staircase effect and layering in FDM lead to poor surface finish and uneven roughness distribution, limiting its efficacy in physical product design, particularly in surface roughness design validation and rapid iteration. In response to the new requirements of national engineering education reform, this interdisciplinary study explores enhancing FDM technology's capabilities in the physical product design process.

In this context, chemical vapor smoothing processes were employed to treat FDM part samples, investigating the variation of surface roughness to achieve control over FDM part roughness. This provides a rapid iteration tool for surface roughness design in physical products. To ensure a controlled and gentle vapor smoothing process, various ratios of acetone and ethyl acetate solutions were mixed and heated to smooth ABS parts. The study observed changes in surface roughness over time for parts with different build angles and analyzed the patterns during the smoothing process. Based on experimental results, appropriate solution ratios were selected for parts with different build angles, and corresponding roughness-time curves were fitted, yielding respective function equations. Finally, to validate the accuracy of these curves, preset roughness values were inputted into the function equations to determine corresponding processing times. The study tested the consistency between the roughness of the parts at these times and the theoretical roughness.

The results indicate that the fitting goodness of the roughness-time curves during the vapor smoothing process exceeded 99\%. In validation experiments, significant consistency was observed in the surface roughness of parts with different build angles, with the maximum deviation from preset roughness controlled within a range of 1 μm. This confirms the accuracy of the curve fitting results and the feasibility of controlling FDM part surface roughness using vapor smoothing processes.

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