Advanced process limits by rolling of helical gears

A new developed method describes the gear-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 for helical gears need additional kinematic compensation during diameter-related variable pitch forming processes. The new 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 tooth-height-coefficient larger than 2,7). The Fraunhofer Institute IWU has carried out research for many years to provide insight in generating high gearing typical of transmissions with rolling techniques and surpassing the limits of forming feasibility.