Numerical Simulation and Experiment of Hot Roll Forming Large Module Gear

To compare with the other gear manufacturing methods, the hot roll forming process is applied in fowling large module gear. The hot gear rolling theory is realized by modeling in Solidworks and Deform-3D, the finite element model(FEM) that coupled deformation and heat transfer was established, and the FE model velocity boundaries were set by converting the workpiece rotation into the revolution speed of the roller. The total displacement of metal flow, folding angel of teeth, effect strain and the temperature distribution of the part were obtained in the whole process of hot gear rolling, also the rolling force was predicted by simulation. The simulation results reveal the forming mechanism, and the rolling experiments were carried out with self-designed rolling mill, which verify that the hot roll forming large gear is feasible.