Gear Rolling Process

Abstract

The rolling process is an efficient alternative to currently exclusively applied cut-ting processes for the production of high gears, particularly regarding economic and ecological aspects. The manufacturing of involute gear profiles by forming, specifically by rolling, has several advantages in comparison to cutting methods, e. g. significantly shorter process times, no material loss and subsequently no chip disposal, strength increase in the forming zone and a high surface quality. Due to these characteristics gear forming will continue to gain relevance in future gear manufacturing. The Chapter presents the efforts being made at the Fraunhofer IWU Chemnitz to reach an advancement of the high gear rolling process by improving the gearing qualities. It presents the investigation and analysis of the interaction between tools, machine and forming process in gear rolling. The results of measurements on the displacements of workpiece, tools and clamping device during the rolling process of a high gearing are displayed. The setup and results of accompanying simulation of the forming process are also given.