為解決傳統手持式割草機傳動齒輪箱之設計組裝不易、成本過高之缺點，本計畫在已有之錐形齒輪研究成果基礎上，提出以「準漸開線錐形齒輪對」新型式的粉末冶金齒輪設計，以取代割草機齒輪箱傳統素材加工渦線傘齒輪，並以負載測試驗證其可行性。計畫將依序進行以下研究項目： (a) 齒輪齒面設計：根據齒輪嚙合理論建立嚙合齒面數學式，並根據強度需求設計齒根過渡曲面； (b) 嚙合關係與強度分析：透過齒輪對嚙合分析，探討組裝誤差下齒端接觸之敏感度，並以齒輪受負載齒面接觸分析與有限元素分析軟體，計算錐形齒輪對齒面接觸應力，以及齒輪齒根彎曲應力，以得到可實務應用的設計； (c) 測試齒輪加工：為降低開發成本，將以粉末冶金燒結後齒胚，以切削方式加工測試齒輪； (d) 負載測試：將製作一汎用型、低負載之直交角粉末冶金齒輪負載測試平台，並以此平台進行負載測試，包括靜態破壞、動態（疲勞）破壞與耐久運轉等測試，以驗證此一新型式設計之粉末冶金燒結齒輪之可行性與可用性，並可觀察粉末冶金行星齒輪機構破壞狀況，以做為後續模具製作之參考。本計畫完成後除可開發出符合經濟效益之割草機齒輪箱粉末冶金齒輪箱，並可進一步設計任何角度直交軸粉末冶金錐形齒輪傳動機構。 In order to solve the disadvantages of the conventional gearbox design of the brush cutter, such as difficulties in assembly, high cost, we propose a new type of powder metal gears by using a quasi-involute conical gear pair to substitute the conventional spiral bevel gear based on the research results in the past years. The project will include the following research topics: (a) Designing the gear flanks: the active gear flanks will be constructed mathematically based on the theory of gearing, and the fillet surface is designed according to the requirement of the bending strength. (b) Meshing and strength analysis: the sensitivity of the edge contact due to the misalignment of axis, contact stress distribution calculated by the loaded tooth contact analysis approach and also the tooth bending stress calculated by the FEM, are discussed. And then a suitable design of the conical gear pair can be obtained for the practical application. (c) Manufacturing of test gears: the test gears will be machined from P/M gear blanks in order to reduce the development cost. (d) Load testing: A general purpose, low load test rig will be constructed for P/M gear drives with intersecting axes. Three kinds of test will be conducted on the test rig to validate the usability and feasibility of the proposed P/M gear drives, namely the static fracture test, the fatigue fracture test and the durability running test. After the project, not only a cost-efficient P/M gearbox for brush cutters can be developed, but also P/M conical gears with arbitrary shaft angles can be designed and validated on the test rig. 研究期間：10006 ~ 10105
