A Study of the Effects of Reversal Cycles in the Gear Rolling Process by Using Finite Element Simulations

Gear rolling is a new gear manufacturing process which can partly replace traditional gear milling processes. High gear wheels with modules of 4mm up to 6mm are of interest to truck manufacturing. The process is of interest since it involves no material removal and since it has the potential to give good performance of the gear wheels. The process must be adopted for the large plastic deformations which occur for gear rolling with large modules. In this paper special emphasis will be put to loads and torques during the gear rolling process of gear wheels with large modulus. The FE method will be used to model the plastic deformation process to fully form a gear wheel with the gear rolling method. The radial and axial loads and the torques in this process are predicted. The loads of the process are high compared to the situation for small gear wheels so simulation of load level is essential for the design of rolling machines for high gears.

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“…The change in the sign of the rolling speed in Fig. 3a is related to the application of reversal cycles during the process [4]. Fig.…”

Section: Finite Element Simulationmentioning

confidence: 97%

Process Planning of Gear Rolling with the Finite Element Method

Khodaee

Melander

2014

KEM

Self Cite

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“…Substitute (2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13)(14)(15)(16)(17) to (2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13)(14)(15)(16)(17)(18) to calculate the tooth surface equation.…”

Section: Numerical Simulation Of Face Gear Hot Rollingmentioning

confidence: 99%

“…Kamounchcong 8,9 analyzed and studied the feasibility of cylindrical gear rolling based on the rolling principles. Khodaee and Melander 10 proposed that during the process of cylindrical gear rolling, the mold gear rotating and feeding speed would directly affect the resulted tooth profile. Sasaki et al 11 achieved the tooth profile accuracy of DIN5 by shaping the tool gear and rolling the powder metallurgy helical cylindrical gear.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation and experimental study on hot rolling forming of spur face gears

Deng,

Jiang,

Deng

et al. 2023

Advances in Mechanical Engineering

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Face gear transmission is the transmission mechanism composed of cylindrical gear and face gear. At present, the tooth making method of face gear is still tooth cutting, with low material utilization and low production efficiency. The metal streamlines are cut off, resulting in low fatigue strength of gear teeth. In this paper, the forming of hot rolling was numerically simulated, with which the characteristics of equivalent stress field, equivalent strain field, rolling force variation, and metal flow in the process of rolling were analyzed. Finally, a hot rolling experimental device was set up, by which the face gear test piece was rolled. Then its tooth surface precision was investigated. The research reveals that hot rolling spur face gears is technological feasible and has promising prospects in industrial applications.

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“…Li et al [9] conducted a numerical simulation of the rolling process and investigated the material fow at diferent locations during rolling and the stressstrain at diferent periods of rolling, explaining the causes of "rabbit ear." Khodaee and Melander References [10,11] evaluated the quality of gears by changing the rotation direction of the die and verifed that the rabbit ear could be suppressed to a certain extent by the forward and reverse rotation experiments, and they studied the variation law of the radial, axial load, and torque of the die wheel during the rolling process. Li et al [12] investigated the efect of different process parameters on the tooth defect "rabbit ear" using DEFORM-3D software and verifed it by experiments.…”

Section: Introductionmentioning

confidence: 99%

Gear Tooth‐Forming Mechanism and Experimental Research of a Spiral Bevel Gear Rolling Process Using Local Induction Heating

Wang

Gao

Deng

2023

Mathematical Problems in Engineering

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The gear tooth near-net rolling process is a novel technique to enhance the tooth strength of spiral bevel gears. To study the gear tooth-forming mechanism, high-temperature rheological experiments of the material 20CrMnTiH were conducted using the Gleeble 1500D thermosimulation machine, and numerical simulations of the spiral bevel gear rolling forming process based on local induction heating were performed with the use of DEFORM-3D. According to the numerical and rolling experimental results, it is feasible to produce spiral bevel gears using the rolling process with local induction heating. In order to solve the uneven material flow of the gear tooth during the tests, the material compensation coefficient k for gear forming was proposed and the shape of the gear blank was optimized. The simulation results show that the effective height of the tooth heel-end and toe-end in the optimized design increases by about 1 mm.

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A Study of the Effects of Reversal Cycles in the Gear Rolling Process by Using Finite Element Simulations

Cited by 14 publications

References 2 publications

Process Planning of Gear Rolling with the Finite Element Method

Process Planning of Gear Rolling with the Finite Element Method

Numerical simulation and experimental study on hot rolling forming of spur face gears

Gear Tooth‐Forming Mechanism and Experimental Research of a Spiral Bevel Gear Rolling Process Using Local Induction Heating

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