Diagnosis of involutometric issues in flat rolling of external helical gears through the use of finite-element models

High-volume production of precision external-involute helical gears using flat-rolling is impeded by a number of quality issues. Experimental resolution of these issues is expensive and time consuming. The present study utilizes finite-element models (FEM) to diagnose three of these quality issues and to explore possible solutions. Two- and three-dimensional (2D and 3D) ABAQUS models were developed for a specific gear-manufacturing process and resulting geometries were not satisfactory. Subsequently, 3D DEFORM simulations were developed for the same process. Numerically predicted geometries were benchmarked against actual results obtained through designed experiments. Finite-element modeling and experimental results were correlated and the models were validated. Possible solutions were simulated and analyzed through additional modeling. Results obtained from the initial pass of the 3D models have been promising although progress has been limited by the excessive computational time needed. Frequency of re-meshing, high number of elements due to fine mesh, and changing re-mesh criteria contribute to the computational difficulties.