Abstract
The purpose of this study is to make clear how to occur the involute tooth profile errors in finish roll forming process. There are two type errors after rolling profiles. One is the concave on the generating pitch circle and the other is pressure angle error on the driven side. It is considered that the concave error caused on varying the number of contact teeth on the line of action of driven and follower side. In the roll forming process it is observed that each pair of teeth would have contact earlier than the ideal kinematic beginning of contact, and have also contact later than the kinematic end. In practice the actual length of line of contact becomes more longer than the ideal kinematic length. A model of the actual contact under the applied die loading force are derived, and the calculated profiles are in good agreement with the after rolling profiles.
