Abstract
Finish roll forming by forced displacement can be conceived as a method of eliminating errors in conventional form rolling under constant loads. This method produces a high-precision tooth profile by low-speed form rolling when a high rigid screw or cam is used at the pressurized section. In this study, the high-speed rolling conditions necessary to allow the new method to be applied in practical situations is discussed. The following conclusion was obtained : The module, number of teeth, addendum modification coefficient, prescribed design precision, and material characteristics are necessary for gear design data.Using these data, the precision of a form-rolled gear can be predicted from the relationship between the applied forced displacement of the tool and the theoretically calculated plastic deformation of the tooth profile.This conclusion was verified experimentally. For example, form rolling improves the accuracy of gear of module 5 from JIS class 3 to JIS class 0 or 1 when the loading force of the tool is 4 to 5 kN and the circumferential speed is 7 m/min.
