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

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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Research on the Movement of the Guiding Roll in the Ring Rolling Process

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.101-102.880 ◽

2011 ◽

Vol 101-102 ◽

pp. 880-883

Author(s):

Xue Dao Shu ◽

Min Xiao

Keyword(s):

Numerical Simulation ◽

Angular Velocity ◽

Cross Sections ◽

Rolling Process ◽

Scientific Basis ◽

Ring Rolling ◽

Rolling Equipment ◽

Simulation Results ◽

Ring Rolling Process

The guiding roll is an important part of the ring rolling equipment which plays an important part in stabilizing the rolling and ensuring the quality of product. This paper obtained the formula for instant diameter of ring during the rolling process and established the motion equation of guiding roll. The angular velocity, instant displacements in X and Y direction of guiding roll center were calculated by MATLAB software. The numerical simulation of ring rolling of ring with rectangular cross sections was completed under the ABAQUS/Explicit environment after importing the instant displacement of guiding roll center. The simulation results indicate that the guiding roll could be controlled accurately by the proper method. These research conclusions can provide scientific basis for ensuring the quality of product and accurately controlling the movement of guiding roll during the ring rolling.

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Simulation and Optimization Studies on the Ring Rolling Process Using Steel and Aluminum Alloys

Journal of Engineering Sciences ◽

10.21272/es.2019.6(2).e6 ◽

2019 ◽

Vol 6 (2) ◽

pp. e36-e40

Author(s):

P. S. Teja ◽

M. D. Kumar ◽

R. Krishna ◽

M. Sreenivasan

Keyword(s):

Aluminum Alloys ◽

Angular Velocity ◽

Plastic Strain ◽

Process Parameters ◽

Rolling Process ◽

Ring Rolling ◽

Optimization Approach ◽

Simulation And Optimization ◽

Number Of Cycles ◽

Ring Rolling Process

The current research was carried out using ANSYS to optimize the process parameters for the ring rolling process. In order to optimize the ring rolling process, parameters such as speed, axial roller feed, and driving rollers have been assessed. As a process optimization approach, the optimum values of the parameters and their relationships need to be evaluated. The stress and strain levels were evaluated at various speeds and forces and the critical failure values were determined. The structural steel and aluminum alloys were chosen for this research because they are used as a roller and job part components in the solid wheels for locomotive applications, respectively. The study was conducted by varying the guide roller’s angular velocity from 40 to 45 rad/sec and varying the work piece’s angular velocity from 200 to 250 rad/sec. Additionally, the work part and roller’s fatigue strengths were determined based on the number of cycles before failure. To evaluate the stresses of plastic strain and von failures, the full stress analysis was also performed. Keywords: roller, ANSYS, workpiece, plastic strain, von Misses stress, metal alloy.

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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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Transmission Errors and Noise of Spur Gears Having Uneven Tooth Profile Errors

Journal of Mechanical Design ◽

10.1115/1.3454048 ◽

1979 ◽

Vol 101 (2) ◽

pp. 268-273 ◽

Cited By ~ 5

Author(s):

I. Yuruzume ◽

H. Mizutani ◽

T. Tsubuku

Keyword(s):

Testing Machine ◽

Spur Gear ◽

Tooth Profile ◽

Spur Gears ◽

Profile Error ◽

Gear Noise ◽

Transmission Errors ◽

Profile Errors ◽

Tooth Profile Errors ◽

Gear Rolling

The problems of involute spur gear noise and transmission errors are studied by meshing m3, 40z spur gears. Five kinds of tooth profile errors, such as convex, concave and wave-like, were formed on the test gear teeth by grinding. The value of each tooth profile error is divided into 3 grades, according to the Gear standards of JIS. Transmission errors of 15 test gears and a master gear were measured by a single flank gear rolling tester with a planetary gear system. Gear noise and strains near tooth fillets were measured by running these test gears on a gear noise testing machine with a power absorbing system, in an anechoic room. This paper presents experimental results and studies of the influence of tooth profile error forms on single flank rolling errors, situation of tooth contacts and gear noise while running.

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