Virtual Design And Numerical Analysis On Cylindrical Gear Rolling Process

Gear plastic forming process including forging, rotary forging, extrusion, cross wedge rolling and cylindrical rolling become an more energy conversation way to produce gears as the extensive use of gears and improvement of gear manufacturing technologies. The gear forming processes have been concerned and studied in these years.Gear cylindrical rolling is a new process, it based on the character of gear engagement, drive the rollers by machine to make the surface metal of workpiece occur plastic deformation to fill the gap between roller and workpiece until complete profile formed. In the forming process, metal flowing, smooth movement of rollers, forming force, physical distribution will change with the roller and time. However, standard theoretical system of gears forming has not been established, the impact of axial force to the process is not sure, and the size and movement parameters of roller and workpiece should to be assured by experiment because of lack gear forming theory and data. So cylindrical gear rolling process was simulated and analyzed in this paper, the feasibility of gear rolling process was verified.Research and results of cylindrical gear rolling process:(1) The establishment of rolling model:calculated dimensions of workpiece and roller, chose movement parameters of roller, established rolling model of gear rolling.(2) Gear rolling mechanism:simulated and analyzed gearing rolling process by DEFORM-3D finite element analysis software (DEFORM-3D). The mechanical load, workpiece deformation and metal strain had been got to analyze metal flow of workpiece. Stress field and temperature field were observed. And the fold could be seen in the DEFORM-3D.(3) Gear rolling process and optimization:the cylindrical gear rolling process had been simulated and the process parameters had been analyzed, the size of workpiece had been optimized based on deformation conditions. (4) Forecast and analysis of gear rolling defects:defects of cylindrical gear rolling process had been predicted and analyzed, optimization method had been proposed.