Numerical simulation and experimental study of slippage in gear rolling

Gear rolling has the advantage of efficient material application, contour-related fiber orientation, and can overcome forming difficulties of gear forging. In the initial stage of gear rolling, often the slipping phenomenon occurs. Slippage and the degree of slippage significantly affect the forming quality of the tooth shape. In this paper, the applied forces on a blank in the initial forming phase of the gear rolling were analyzed, and the main factors affecting slippage were determined. Then, the quantitative evaluation index of the slippage was established. The effect of initial bite depth, friction condition, and number of teeth on the gear roller on slippage was obtained using finite element analysis. The effect of different initial bite depths and number of teeth on the gear roller on the slippage was studied experimentally. Moreover, the reliability of the finite element simulation results of gear rolling was verified. The results can provide a scientific basis for establishing reasonable process parameters, control of slippage, and improving the forming quality in gear rolling.