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A new method for preform dimension and influence of relevant parameters in the gear forced throughfeed rolling process

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Abstract

Gear rolling process is an advanced forming technology in which the rolling die extrudes the preform material to flow plastically and finally form desired gears, and the preform dimension has a decisive impact on the quality of the final formed gears. To further explore the influence of tooth-tip defects on the tooth height of the formed gears in the forced throughfeed rolling process, and ensure the quality of the formed parts, a new computational method for the preform dimension was firstly proposed. A growth coefficient model based on the effective top circle of the formed gears was also given. Then, the dependence of the effective top circle size in regard to geometric parameters and material of the formed gears such as the number of teeth, module, and pressure angle were explored by the established model and finite element analysis (FEA). Finally, the experimental results were displayed to verify the proposed computational method and theoretical model. The results show the growth coefficient increases with the increase of the number of teeth and module, and decreases as the pressure angle increases. Moreover, the material with better plastic deformation ability contributes to improving the growth coefficient. Additionally, the proposed new method and theoretical model for preform dimension calculation could be adopted in the gear rolling.

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Abbreviations

α :

Pressure angle of pitch circle, deg

α C :

Pressure angle of outside circle in which point C is located, deg

α F :

Pressure angle of outside circle in which point F is located, deg

α Q :

Pressure angle of outside circle in which point Q is located, deg

θ Q :

Angular coordinate in the polar coordinate, rad

r b2 :

Base circle radius of the formed gears, mm

r f2 :

Root radius of the formed gears, mm

r 2,0 :

Initial radius of the preform, mm

\( {r}_{\mathrm{a}2}^E \) :

Effective tip radius of the formed gears, mm

\( {r}_{\mathrm{a}2}^R \) :

Actual tip radius of the formed gears, mm

r C :

Radius of outside circle in which point C is located, mm

r Q :

Distance between point Q and pole in the polar coordinate, mm

s r :

Area of tooth-tip defects on the cross-section, mm2

s t :

Area between top circle and root circle on the cross-section, mm2

s T :

Area above the root circle of single tooth with considering tooth-tip defects, mm2

v b :

Material volume of end-flow on single tooth, mm3

B :

Tooth width of the formed gears, mm

z 2 :

Number of teeth of the formed gears

m :

Module of the formed gears, mm

K :

Growth coefficient of the formed teeth

h * :

Addendum coefficient

c * :

Clearance coefficient

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Funding

This project is supported by the National Natural Science Foundation of China (No. 51775062), Shanxi Province Science Foundation for Youths (No. 201901D211292), and Initial Scientific Research Foundation of Taiyuan University of Science and Technology (No. 20192022).

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Authors and Affiliations

  1. School of Mechanical Engineering, Taiyuan University of Science and Technology, Taiyuan, 030024, China

    Ziyong Ma, Lifeng Ma & Weitao Jia

  2. Collaborative Innovation Center of Taiyuan Heavy Machinery Equipment, Taiyuan, 030024, China

    Ziyong Ma, Lifeng Ma & Weitao Jia

  3. College of Mechanical Engineering, Chongqing University, Chongqing, 400044, China

    Ziyong Ma, Yuanxin Luo & Yongqin Wang

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  1. Ziyong Ma
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  2. Lifeng Ma
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  3. Yuanxin Luo
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Correspondence to Yuanxin Luo.

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Ma, Z., Ma, L., Luo, Y. et al. A new method for preform dimension and influence of relevant parameters in the gear forced throughfeed rolling process. Int J Adv Manuf Technol 107, 3553–3567 (2020). https://doi.org/10.1007/s00170-020-05313-x

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