齒輪在動力傳輸中扮演不可或缺的角色，螺旋傘齒輪(spiral bevel gear)由於強度高、運轉平穩與噪音低等優勢，被廣泛應用於高負荷、高轉速的機械系統中，然而其齒面幾何較複雜，大多以齒輪專用機進行製造，缺乏設計或生產的彈性。本研究嘗試以泛用型的五軸工具機，完成螺旋傘齒輪的加工製造，為提高材料移除率，將採用五軸側銑切削，將刀具路徑規劃轉換成數學規劃問題，利用全域最佳化演算法求解刀具運動，降低共軛齒面的加工幾何誤差。並以刀具運動包絡面估算誤差值，期望透過最小化曲面加工誤差，提升齒輪的齒面接觸分析品質，以及動力傳輸效率。此外提出一項簡化的評估方法，以嚙合齒面之間的相交幾何，近似基於有限元素法的齒面接觸分析結果，並透過實際範例顯示其正確性。本研究透過五軸側銑的路徑規劃，產生接近理想齒面的加工結果，藉此得到較佳的齒面嚙合表現，驗證以泛用型切削技術，製造螺旋傘齒輪的可行性。研究成果應可提高螺旋傘齒輪的開發效率，與其生產製造的彈性。

Gear is an important mechanical element in power transmission. Spiral bevel gears provide several advantages over spur gears such as high transmission efficiency, low noise, and smooth running. However, the gear manufacturing requires specialized machines and cutting tools with very limited production flexibility, due to the intricate gear geometry. This research developed a precision tool path planning method for five-axis flank milling of spiral bevel using general-purpose machine tools. The method reduces the geometrical errors produced on the pinion gear by adjusting the tool path defined by three free-form curves describing the moving trajectory of the cutter center point, the variation of the tilt and yaw angles, respectively. A meta-heuristic algorithm incorporating the curve subdivision technique is applied to search for optimal solutions of the curve control points. The Tooth Contact Analysis (TCA) results indicate that the pinion gear created by the optimal tool path outperforms the one produced by the previous planning method, in which the cutter contacts the center curve of the gear surface. We have shown that optimization-driven tool path planning enables precision five-axis machining of spiral bevel gears. This research provides a feasible method for gear manufacturing using generalized CNC machine tools, and thus increases the development efficiency and production flexibility of spiral bevel gears.

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