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Finite Element Analysis on the Friction Effects in the Gear Rolling Process
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: NEWTECH 2013, 2013Conference paper (Refereed)
Abstract [en]

Gear rolling as a manufacturing method for gear wheels has a number of advantages in comparison with traditional gear production methods which makes it an interesting topic for scientific research. The main benefits are reduced material consumption, fast cycle time of the process, improved strength of the product due to the alignment of the microstructure during cold forming and a good surface quality.

There are several factors which can influence the process quality and accuracy of the geometry in the final state. One of the most important parameters is the friction between the tool and the blank during the forming process. Therefore it is of interest to study the effect of different friction models in finite element simulations to evaluate its effects on final gear wheel shape.

In this paper the shear friction model is studied. Two friction factors will be studied in this case. Two dimensional FE calculations will be performed with the code DEFORM. The results of the FE simulations and the effect of friction factor on gear flank and tip geometry are presented. One example is presented of the effect on the so called “rabbit ear “at the gear tip.

Place, publisher, year, edition, pages
Keyword [en]
Gear rolling, Friction, FEM, Metal Forming
National Category
Production Engineering, Human Work Science and Ergonomics Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production; SRA - Production
URN: urn:nbn:se:kth:diva-137068OAI: diva2:677850
NEWTECH 2013, International Conference on Advanced Manufacturing Engineering and Technologies
XPRES - Initiative for excellence in production research

QC 20140212

Available from: 2013-12-10 Created: 2013-12-10 Last updated: 2015-09-14Bibliographically 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.
TRITA-IIP, ISSN 1650-1888 ; 15:06
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production; Production Engineering
urn:nbn:se:kth:diva-173510 (URN)978-91-7595-678-7 (ISBN)
2015-09-29, M 311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)

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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