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Finite Element Simulation as a Tool to Evaluate Gear Quality after Gear Rolling
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Welding Technology.ORCID iD: 0000-0003-1021-0100
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Welding Technology.ORCID iD: 0000-0002-6061-662X
2013 (English)In: Current State-Of-The-Art On Material Forming: Numerical And Experimental Approaches At Different Length-Scales, Pts 1-3, Trans Tech Publications Inc., 2013, Vol. 554-557, 300-306 p.Conference paper, Published paper (Refereed)
Abstract [en]

Gear rolling is a manufacturing technique for gears with many advantages like reducedmaterial consumption, reduced scrap generation, fast cycle times, good surface quality andimproved final properties of the gear wheels compared to conventional production technology basedon machining. In order to make use of all these advantages it is desired to reach the final shape ofthe gear wheel already after rolling. This means that post treatments like grinding should beavoided. This puts high requirements on the shape accuracy after gear rolling.In this paper it was studied if finite element simulation could be used to evaluate the shape accuracyafter gear rolling. The measurement of shape accuracy of gear wheels is specified in standards likeISO1328-1. The allowed deviations from nominal shape are often of the order of 10-30 μm for verygood qualities. So if such evaluation shall be possible from a finite element simulation the accuracymust be of the same order.In order to have sufficient accuracy of the finite element simulation 2D simulations were performedon a spur gear. The FE code DEFORM was utilized. The shape accuracy was evaluated for gearrolling of two cases. One case had gears with the module of 1 mm. The other case involved gearswith a significantly larger module of 4 mm. This was an interesting case since it is known that it ismore difficult to roll the gear with good accuracy in large modules.

Place, publisher, year, edition, pages
Trans Tech Publications Inc., 2013. Vol. 554-557, 300-306 p.
Series
Key Engineering Materials, ISSN 1013-9826 ; 554-557
Keyword [en]
Gear Rolling, Finite Element Method, Gear Quality Evaluation, Rolling of Large Module Gears
National Category
Engineering and Technology
Research subject
SRA - Production
Identifiers
URN: urn:nbn:se:kth:diva-105406DOI: 10.4028/www.scientific.net/KEM.554-557.300ISI: 000322092100035Scopus ID: 2-s2.0-84880552390ISBN: 978-303785719-9 (print)OAI: oai:DiVA.org:kth-105406DiVA: diva2:570874
Conference
16th annual ESAFORM Conference on Material Forming; Aveiro, Portugal, 22-24 April 2013
Funder
XPRES - Initiative for excellence in production research
Note

QC 20130905

Available from: 2012-11-20 Created: 2012-11-20 Last updated: 2016-02-26Bibliographically approved
In thesis
1. Gear Rolling for Production of High Gears
Open this publication in new window or tab >>Gear Rolling for Production of High Gears
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Gears are used to transmit mechanical workfrom one point to another. They are widely used in different mechanisms and they are the most important components of a transmission system. Thus, it is important that they are manufactured with high precision to deliver the work with highest possible efficiency. The dominant gear production method is metal cutting, like hobbing. The gear manufacturing industry aims to replace their traditional production lines with greener processes and thereby urge engineers to think about using metal forming methods instead of the traditional metal cutting solutions when possible. Gear rolling is an interesting metal forming method that can be an alternative method to fabricate gear wheels.

Research on gear rolling firstly came into interest around 2000. Very few papers are published that covers the development of the method and its limitations and advantages. Almost all of these publications considered rolling of gear wheels with small modules. The focus of this study will be on application of gear rolling for gear wheels with large module (over 3 mm) where the amount of deformation is much larger than found in previous studies.

In this thesis the Finite Element Method has been used to simulate and predict the results of rolling of high gears. In addition to that experiments were performed to validate the numerical results and develop the modelling technique for further investigations. The main topic of discussion is about the gear quality as a measure of the success for the process. Extra attention has been paid to the effects of friction and process planning in the result of process loads and also on the gear quality.

The thesis structure is based on four published papers, and some additional results from the experiments which have not yet been published. According to the results of these papers, the effect of friction and process parameters are recognized in the final product quality. It is shown that FEM has a great potential in order to model and analyze the gear rolling process. A new approach to combine numerical methods with quality measurement to predict the process outcomes is also presented. The results show that gear wheels with a module of 4mm reach an ISO quality level between 11 and 12. This is substantially lower quality than can be obtained with metal cutting operations. The results of this thesis can be used as the starting point for future research to optimize the quality of gear rolling for high gears.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. v, 73 p.
Series
TRITA-IIP, ISSN 1650-1888 ; 15:06
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production; Production Engineering
Identifiers
urn:nbn:se:kth:diva-173510 (URN)978-91-7595-678-7 (ISBN)
Presentation
2015-09-29, M 311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Funder
VINNOVA, FFI SMART
Note

QC 20150914

Available from: 2015-09-14 Created: 2015-09-14 Last updated: 2015-09-14Bibliographically approved

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Khodaee, AlirezaMelander, Arne

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