Influencing factors of effective tooth depth in the cylindrical gear rolling process with axial infeed

Gear rolling is a new gear manufacturing process which can partly replace traditional gear milling processes. High gear wheels with modules of 4mm up to 6mm are of interest to truck manufacturing. The process is of interest since it involves no material removal and since it has the potential to give good performance of the gear wheels. The process must be adopted for the large plastic deformations which occur for gear rolling with large modules. In this paper special emphasis will be put to loads and torques during the gear rolling process of gear wheels with large modulus. The FE method will be used to model the plastic deformation process to fully form a gear wheel with the gear rolling method. The radial and axial loads and the torques in this process are predicted. The loads of the process are high compared to the situation for small gear wheels so simulation of load level is essential for the design of rolling machines for high gears.

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Effect of variation of angular velocity in gear rolling process on profile error

Precision Engineering ◽

10.1016/s0141-6359(02)00125-3 ◽

2002 ◽

Vol 26 (4) ◽

pp. 425-429 ◽

Cited By ~ 5

Author(s):

Seizo Uematsu

Keyword(s):

Angular Velocity ◽

Rolling Process ◽

Profile Error ◽

Gear Rolling

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A Study of the Effects of Reversal Cycles in the Gear Rolling Process by Using Finite Element Simulations

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.611-612.134 ◽

2014 ◽

Vol 611-612 ◽

pp. 134-141 ◽

Cited By ~ 7

Author(s):

Alireza Khodaee ◽

Arne Melander

Keyword(s):

Finite Element ◽

Gear Wheel ◽

Quality Criteria ◽

Rolling Process ◽

Work Piece ◽

Feed Speed ◽

Cylindrical Blank ◽

Rotation Direction ◽

Innovative Methods ◽

Gear Rolling

The manufacturing of machine components with sustainable and innovative methods is an interesting topic for research. Gears are some components which have complexity in both design and production technology. Therefore applying innovative methods on gear manufacturing can be of interest to industry. One of the most promising production methods for gear wheels is Gear Rolling. The gear wheel is formed during a certain rolling process from a cylindrical blank into the final designed shape. The process of gear rolling with rotational gears is progressing by running several rolling cycles with one, or two dies in contact with a work-piece. A specified rotational speed and radial feed speed is applied to the dies in order to form the required geometry on the blank. In this paper, the authors have simulated the process with the finite element code, DEFORM 3D. Especially the effects of reversal cycles on final gear wheel geometry have been evaluated from the simulations. Different settings for the rotation direction of the dies have been used and the effects are evaluated with specific quality criteria.

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