Straight Tooth Cylindrical Gear Wheel Rolling Based On The Principle Of Cross Wedge Rolling

With the development of modern industry, all kinds of machinery are more and more common. However, gear shaft is a component of an integral part of the machinery, so the demand of the gear shaft is increasing day by day. Now, however, processing method mostly is adopted by machining, the method of material utilization rate is low with complex process and owing to the removal of material molding method, rough pieces of metal fiber has been destroyed, which greatly reduces the strength of the gear shaft. Therefore, we urgently need a new, efficient method which can obtain relatively high quality gear shaft processing.The use of cross wedge rolling process of gear shaft can not only enhance the strength of the gear shaft, but increase the processing efficiency and improve the utilization ratio of material. Because the shape of tooth profile influences the quality of the gear shaft in a great extent, we rolled gear shaft on the basis of the principle of roll cross wedge rolling and focus on the process parameters and the factors affecting the forming of the gear tooth profile in the cross wedge rolling process. This paper has great research value in theory and application.This paper describes the theoretical basis for the subject, briefly introduces the basic theory of cross wedge rolling theory, the basic theory for finite element method and RPFEM used in cross wedge rolling process. Taking the rolling gear shaft molding characteristics into account, rigid-plastic finite element model is used to analyze the roll-forming process.For a specified gear shaft, firstly draw out its two-dimensional CAD drawings and design its rolling die according to its two-dimensional drawings.Then use UG to transform the two-dimensional mold into a three-dimensional model and create a numerical finite element model. And it was simulated by deform. The influence of the parameters and the change of the diameter of roughcast on the rolling process is studied. In the simulation process appeared a series of defects (such as the workpiece which is not easy to rotate, large amount of slip, disorderly tooth, tooth which is not full).By changing the rolling technology and simulation parameters again and again, we repair the defect successfully,and get the perfect tooth profile of gear shaft.The tooth profile obtained by rolling as the final main indicator in this paper, we design test plan by control variable method, study and analyze the influences of gear tooth modulus and tooth number on the forming quality. Then we acquire the best modulus of toothed rolling and the most suitable number of teeth..