Abstract
This paper describes a new method and its results in the roll-forming of gears that has significantly surpassed the conventional limits known till now. The method describes the rolling process and an alternative pitch design of forming tools. A model was created to analyze rolling processes which determined that in contrast to flat rolling tools, round tools need additional kinematic compensation during diameter-related variable pitch forming processes. This presented method shows up to a 50 % improvement in pitch accuracy and the ability to roll high teeth gears (up to 10 mm in height and a toothheight-coefficient larger than 2).