Interaction of machine, tool and process by rolling of high gears

The rolling process is an efficient alternative to currently exclusively applied cutting processes for the production of high gears particularly regarding economic and ecological aspects. The manufacture of involute gear profiles by forming, specifically by rolling, in comparison to cutting methods has the following advantages: \'01 short process time, \'01 no material loss and subsequently no chip disposal, \'01 strength increase between 60% (flank area) and 100% (tooth root area), \'01 high surface quality (Ra = 0,2 - 0,4?m; Rz = 1,0 - 1,4?m), \'01 load adapted fibre orientation and lower shape distortion in heat treatment. Due to these characteristics gear forming will continue to gain relevance in future gear manufacturing. Prerequisite for the advancement of the high gear rolling process is the improvement of the gearing qualities regarding the profile line, flank line and pitch accuracy of the involute gear profiles. The paper presents the investigation and analysis of the interaction between tools, clamping device and forming process in gear rolling. In the examination a specifically designed laser tracker measurement system has been used in order to collect data on the rolling process regarding vibration and displacement of the clamping tool and tool bearing. Due to the novelty of the process the existing rolling machine concepts aren't adapted to the specific demands of high gear rolling. During the process vibrations occur at various intensity levels, which are determined by the tool geometry, the gearing characteristics and the positioning of tool and workpiece relative to each other at the process start. Furthermore, the impact and contact of the tool tooth with the workpiece in the tooth gap, influences the process. As a result of the laser tracker analysis a shift of the tools from the axial position has been confirmed. This shift and the conventional clamping system result in a suboptimal rolling kinematics. The profile, pitch and flank line deviation of the rolled gear increases and the gearing quality (DIN 3960 - 3962) decreases.