Experimental-Numerical Investigation of the Rolling Process of High Gears

Abstract

Rolling of high gears into full material is a new and economic way of manufacturing. Such gearings provide a higher surface strength and a better surface quality than conventional gearings. However, higher expenses for tools are disadvantageous. So far, the design of the forming tools follows only geometric requirements and the loads at the tool surface are not considered for designing these tools. To increase the life cycle of the tools, the loads at the tool surface and the stress state at the contact zone have to be taken into account. This paper presents an experimental setup to record strain data at the forming tool during the processing. Results of these measurements are shown for several stages of the process. Numerical simulations, according to the experimental tests, are shown in the second part. A staggered simulation with a two‐dimensional model of the forming process is used to identify contact loads at the tool surface. These loads are transferred to a three‐dimensional numerical model of the forming tool and the procedure to transfer loads is described in this article. The validation of the numerical results with the measured strain data shows the applicability of the numerical approach for designing tools.

Material Flow Analysis in Indentation by Two-Dimensional Digital Image Correlation and Finite Elements Method

“…Nowadays, new complex functional components are demanded with reduced weight and local strength, for example, for gear elements manufacturing. Localized forming operations are an interesting alternative to conventional machining processes [ 3 ]. As a manufacturing process, indentation is increasingly adapting to the metalworking industry.…”

Finite element modeling and analysis for the integration–rolling–extrusion process of spline shaft

“…The new process was verified through finite element (FE) method. Similarly, using the FE method, the rolling process of high gears was studied by Kretzschmar et al 17 Zou et al 18 have designed the optimal die profile which yields more uniform surface-load distribution on die profile surface via integrating FEA during the hot extrusion process. The work can improve the die life in hot extrusion processes.…”