A Study on Reducing the Gear Tooth Profile Error by Finish Roll Forming

This paper deals with the tooth profile error of spur gears that have been finished by roll forming. First, we present experimental data that confirms that the tooth profile error is a synthesis of a concave error and a pressure angle error. Since various types of tooth profile errors appear in the experiments, evaluation parameters are introduced for rolling gears so that profile quality may be objectively evaluated. Using these evaluation parameters, the relationship among the tooth profile error, the addendum modification factor (A. M. factor), and the tool loading force are verified. The character of concave error, pressure angle error and tool loading force of finish roll forming by using a forced displacement method are verified. This study makes clear that the tool loading force of finish roll forming is a very important factor that affects involute tooth profile error. The results of the experiment and analysis show that the proposed method reduces both concave and pressure angle errors.