Design And Development Of Spur Cylindrical Gear Roll Forming Experimental Device

Gear is the most widely used mechanical transmission parts. With the increasing demand for gears and the increasing accuracy and mechanical properties required for forming gears, high precision and high efficiency of the production gear is the inevitable trend of development. Combining the characteristics of roll forming and the advantages of precision forging, a new approach roll forming process of the spur cylindrical gear is put forward. With less raw material consumption, low input costs, high production efficiency, high forming precision, roll forming process has lots of advantages. Contact fatigue strength, flexural strength, impact strength and wear resistance of shaped gears are all improved and it effectively solves issues of forging or extrusion molding gear, such as tooth cavity filling material shortage, large shaping force and stripping difficult. Currently, researches for gear roll forming process are basically in theoretical or experimental research stage and the development of equipment for spur cylindrical gears roll forming is rarely. This paper will expound the design and development of spur cylindrical gear roll forming experimental device.Based on the principle of gear roll forming process, the analysis shows the basic structure and movement of the experimental device. According to the structure diagram of experimental device, the layout has been designed and optimized to define the overall layout program of the experimental device.By contrast gear roll forming process to determine the rolling step, with DEFORM-3D software to build gear rolling model, the numerical simulation analysis of gear roll forming reflects the required rolling force and rolling moment of the whole roll forming process, guiding the design of gear roll forming experimental device. Design the structure of parts of gear roll forming experimental device and check their strength. According to the power, torque, speed and other requirements of the experimental device, match suitable servo motor, reducer and PLC, etc.. Complete parts manufacturing and the final assembly of experimental device. In view of the problem of gear rolling process, improve the experimental device constantly.In order to verify the feasibility of gear roll forming process scheme and the accuracy and reliability of finite element numerical simulation analysis, roll forming experiments are carried out with the experimental device to test the reliability of experimental device designed. The effect of different initial biting amount of slippage between the rolling gear and blank is experimented to verify the accuracy of the experimental device. The error analysis of the experimental process is carried out, with the existing problems analyzed, and the improvement measures are given.