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Round rolling process of spur gears

: Neugebauer, Reimund; Müller, Roland; Hellfritzsch, Udo; Lahl, Mike; Schiller, Sven; Milbrandt, Matthias; Druwe, Thomas

Preprint urn:nbn:de:0011-n-1833663 (1.1 MByte PDF)
MD5 Fingerprint: 83f9a262f6189645373b70230cb94216
Erstellt am: 22.11.2011

Slabe, E. ; TECOS Slovenian Tool and Die Development Centre, Celje:
Industrial Tools and Material Processing Technologies : Proccedings of the 8th International Conference on Industrial Tools and Material Processing Technologies, October 2nd-5th 2011, Ljubljana; ICIT & MPT 2011
Ljubljana, 2011
ISBN: 978-961-6692-02-1
International Conference on Industrial Tools and Material Processing Technologies (ICIT&MPT) <8, 2011, Ljubljana>
Konferenzbeitrag, Elektronische Publikation
Fraunhofer IWU ()
gear rolling; cross rolling; hybrid analysis; finite element method; visioplasticity

The paper deals with the rolling process of gears and profiles, which demonstrates a seminal energy and material
efficient forming technology for the production of lead geometries of Power Train applications. Former cold rolling
processes for gear production only gained industrial acceptation for assortments of stub-toothed geometries until a tooth height factor of y = 1.5. Results and findings of the researches at the Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz prove, that it is possible to produce high gearings for transmission applications (tooth height factor y < 2.8), as well as other rotationally symmetric profile shapes by round rolling technique.
The paper presents the efforts being made to enhance the usability of this technique. Several experiments and
simulations to detect stresses and the material flow in the forming zone are illustrated. The results of these works lead to an optimization of process parameters to assure an efficient forming process.
The paper discussses the possibilities of process optimization, tool design, construction, available computing
capacities and the latest findings in the simulation of incremental forming technologies.
Further more the three-dimensional component material flow, the maximum achievable deformation, the work piece
strain hardening, the gradient of material fibre and the occurring tool and work piece loads were computed in acceptable calculating time by using different simulation software and verified by practical investigations.