Simulations of Gear Rolling by Flat Tools

Gear rolling is one of the latest techniques being used in gear manufacturing. As compared to traditional gear manufacturing techniques, gear rolling can add benefits like improved surface finish, increased flank strength, increased load capacity and less material usage. After initial research initiatives in USA, Germany and China, efforts are underway to make this technique industrially viable for production of both low and high module gears. There are two methods for gear rolling one uses round tools while other uses flat tools. The current work examines advantages and limitations associated with gear rolling by flat tools. A finite element simulation software has been used to analyze the process and results are compared with actual gear to confirm viability of the process. The results of the simulations validate the previous findings about gear rolling and provide a base for future developments in this field.