本論文探討基於全域搜尋之五軸側銑加工路徑最佳化問題，分別就提高應用價值與計算效能兩方面，進行創新性的研究。首先結合五軸切削力學模型，根據切屑幾何的估算，預測不同刀具位置對應的切削力；並透過刀具位置與軸向的改變，產生較佳的切削力學狀態。將此機制整合至加工路徑規劃的最佳化演算法中，在限制瞬時最大切削力的條件下，以降低曲面加工誤差為目標，經由粒子群演算法求得最佳化刀具路徑。此外提出決定刀具分布位置的方法，根據曲面的扭曲值、邊界弧長差異與平均曲率等三種幾何性質，適當選擇組成加工路徑的刀具位置，藉此改善最佳解的品質。透過模擬結果的驗證，已顯示本研究概念的可行性，不僅有效控制五軸側銑的切削品質，亦能進一步減少曲面加工誤差。最後提出將曲面之可展開性最佳化的方法，實際應用於輪胎模具的製造上，並透過實體切削驗證研究概念的可行性，結果顯示不僅可以在切削誤差上有顯著的改善，亦能提升路徑規劃之計算速度，並提升研究概念的實用性。本研究採用演化計算方法，整合實際切削的物理模型，開啟數學規劃於實際製造的新穎應用。

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