Gear rolling process is a state-of-the-art technology on track for the future due to the productivity, high material unitization rate and high profile qualities. The pitch error has been one of main concern to fabricate high precision gears. The initial stage is to divide the angular position of teeth, and it has significant impact to pitch error of the formed gear as well as fatigue life of the rolling tools. This paper is aimed to study the two geometrical requirements of dividing teeth in the initial stage that are the phase difference of rolling tools and the contact ratio. The contact ratio is modeled with consideration of the geometric of the forming tool, bite depth, size of the workpiece, etc. A speed-controlled forced synchronization system is proposed for forming large module gear and the rolling experiments demonstrates its effectiveness. Finally, some discussions and conclusions are given.

This content is only available via PDF.
You do not currently have access to this content.