Investigation on the effects of tooth profile deviation in gear rolling process.

Gear rolling is a cold-forming process by using a cylindrical blank to produce gear teeth with high strength, good surface finish, and high material utilization rate. Gear tooth profile deviation is one of the most important factors in evaluating the gear accuracy. In order to understand the forming process of gear tooth, this paper is dedicated to studying the rolling process from geometry relation based on gear mesh theory. Then, the way of material flow to form the gear tooth in the rolling process is investigated by finite element method. The comparison results show that tooth profile rolled by standard rigid body tool still has a certain tooth profile deviation and tooth thickness deviation during the process of one-way rolling. The left side of the rolled gears has a longer effective length and a worse profile deviation than the right side. The increase in material plasticity and a slower increase in reduction are conducive to improving the accuracy of the precision of the formed workpiece the height of the effective tooth profile. This research will be helpful for process parameter selection and subsequent research for defect compensation. [ABSTRACT FROM AUTHOR]