Optimization Study on the Tooth Profile of Gear Shaping Roller of Honeycomb Semi-Cell Structures

In order to solve the problem of low accuracy of honeycomb semi-cell structures which are rolled by traditional trapezoidal tooth profile gear shaping rollers, conjugate trapezoidal tooth profile gear shaping rollers have been put forward to improve the quality of honeycomb semi-cell structures, basing on the theoretical analysis. Using ANSYS/LS-DYNA, a finite element model of rolling aluminum foils by two kinds of tooth profile shaping rollers was set up. Then results of numerical simulation indicate that the honeycomb semi-cell structures rolled by the conjugate trapezoidal gear shaping rollers are closer to the ideal size than those rolled by the traditional trapezoidal gear shaping rollers.