鍛造在現今的製程中為最有效率的一種方式，具有高強度以及高生產率等優點，所以經常被應用在傘齒輪的製造上。然而鍛造傘齒輪的精度仍不及機械加工出產的傘齒輪，其主要原因在於鍛造過程中，胚料與模具材料的彈性變形較不易掌握，加上螺旋傘齒輪齒厚不均，易造成齒面變化不規律，因而無法有效控制傘齒輪鍛造精度。
本論文提出鍛造螺旋傘齒輪齒面誤差修正方法。首先根據美國格里森公司提出的SGDH切製法(Generated Spiral Bevel Gears, Duplex–Helical Method)來建立螺旋傘齒輪的齒面數學模式，並進行齒面相對修形與齒面接觸分析來評估齒輪對的接觸性能。接著調用SolidWorks API(Application Programming Interface)函式自動產生齒輪對3D模具零件，並於DEFORM-3D軟體上進行螺旋傘齒輪溫鍛與冷鍛模擬分析。將模擬結果輸出STL(STereolithography)檔案與理論齒輪的齒面進行誤差分析比較，並根據齒面誤差結果來修正齒形模具。第一次的齒面分析結果最大誤差為10條，經由來回補償兩次齒面模具後進行齒面分析的結果最大誤差為2條，將齒輪精度提升至DIN8級，驗證本研究提出的齒面修正方法的正確性。

Die forging is the most efficient method in the manufacture of parts. Due to its advantages of high strength and high productivity, forging process is frequently applied in manufacturing bevel gears. However, the forged bevel gears has lower accuracy compared to the machined one. The main reason is that it is difficult to control the deformation of blank and molds during forging process. In addition, uneven tooth thickness of bevel gear leads to irregular deformation on gear surface. Therefore, the precision of forged bevel gear cannot be effectively improved.
In this study, a flank correction method of forged spiral bevel gear is proposed. First, tooth surface of spiral bevel gears are constructed by Gleason SGDH Method(Generated Spiral Bevel Gears, Duplex-Helical Method). The contact performance of gear pair is evaluated using ease-off and tooth contact analysis. A developed program based on SolidWorks API (Application Programming Interface) is then used to automatically create 3D gear parts for design of molds. The deformation of forged gear under warm forging and cold forging is analyzed using DEFORM-3D software, and the simulated part can be exported to a STL(STereoLithography) file for further investigating on tooth flank from deviations compared with the theoretical tooth surface. The tooth surfaces of mold are appropriately amended based on the tooth surface deviations. According to the experiment results, the flank topographic analysis shows that the maximum deviation of tooth surface of molded gear is about 0.1mm before correction. However, after two corrections, the maximum deviation can be reduced to 0.02mm. It proves that the proposed flank correction method can effectively improve the geometric accuracy of tooth surface of molded gear.

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