Influence of process parameters on gear rolling process

Gear rolling forming is a new technology that makes metal billet produce plastic deformation continuously under the action of the die with tooth profile rotating in the same direction, and finally forms the gear. Compared with other forming processes, roll forming has the advantages of less consumables, shorter production cycle and smaller forming load. In addition, the metal fiber flow of the formed gear is linear distribution, and the metal fiber is not interrupted by machining, so the mechanical properties of the formed gear are excellent. In recent years, with the continuous development of numerical calculation method, finite element analysis method and plastic forming theory, scholars at home and abroad have also increased their attention and Research on roll forming technology.

In the process of gear rolling, because of the relationship between the rolling gear teeth and the blank, the tooth profile of the blank is continuously rolled by the local rolling of the side of the rolling gear. At the beginning of rolling, the engagement of the rolling wheel to the conical blank will produce sliding; the surface of the gear will fold due to the non-uniformity of the dividing teeth and the mismatch between the rotation of the rolling wheel and the feed speed; the tooth profile of the blank is continuously affected by the local position of the rolling tooth side Some defects such as lug will appear at the top of the tooth profile.

It is of great significance to understand the flow behavior of material and the law of tooth profile forming and improve the quality of gear rolling.

The rolling process was simulated by the finite element analysis method, and the flow law of the material in the rolling process was studied. The influence of forming temperature, extrusion speed and friction coefficient on the rolling process was analyzed by orthogonal test.