Simulation research on the control method of bow-collapse in gear cold roll-beating

Ma, Qun (author), Cha, Li (author), Zhang, Xiangwei (author)

Bow-collapse is a type of geometric defect in the gear cold roll-beating process. In order to effectively control bow-collapse and improve material utilization, this paper calculates the cross-section radius of the blank according to the volume invariance principle of metal plastic deformation, and then performs FE simulation of the cold roll-beating process by using the cyclic beating of adjacent tooth spaces and intermittent blank feeding method. The flow state of metal particles is investigated, revealing that the movement of metal particles along the axial direction of the blank is the main reason for the formation of bow-collapse. This paper proposes a method to correct the cross-section radius of the blank and thus control for bow-collapse, where the loss coefficient K characterizes the state of metal particle loss in an infinitesimal thickness region on the cross-section. The analytical equation for calculating the corrected value of the cross-section radius is derived, and the corrected value is calculated. Conducted on the modified blank, cold roll-beating FE simulation results show that bow-collapse is effectively controlled, and the loss coefficient K correctly reflects the loss state of metal particles on the cross-section. The simulation results also show that after cold roll-beating, the gear teeth with standard face width and tooth depth can be obtained after two turning end faces and turning tip circle processes. The bow-collapse control method proposed in this paper effectively improves material utilization.

• Language: English
• Keywords: cold roll-beating, bow-collapse, FE simulation, loss coefficient, cross-section radius
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2024
• Number of pages: Str. 426-439
• Numbering: Vol. 70, no. 9/10
• PID: 20.500.12556/RUL-163907
• UDC: 621.77
• ISSN on article: 0039-2480
• DOI: 10.5545/sv-jme.2023.884
• COBISS.SI-ID: 211355395
• Publication date in RUL: 14.10.2024

Record is a part of a journal

• Title: Strojniški vestnik
• Shortened title: Stroj. vestn.
• Publisher: Zveza strojnih inženirjev in tehnikov Slovenije [etc.] = Association of Mechanical Engineers and Technicians of Slovenia [etc.
• ISSN: 0039-2480
• COBISS.SI-ID: 762116

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Title: Simulacija obvladovanja ločnega posedanja pri hladnem tolkalnem valjanju zobnikov
• Keywords: hladno tolkalno valjanje, geometrijske napake, način obvladovanja, ločno posedanje, simulacija po MKE, koeficient izgub, radij prereza