Abstract
Numerical tooth profile analysis of finish P/M gear rolling process using screw-shaped tool was carried out by the combination method of FEM and linear programming for optimum tool design. The deformation behavior of rolled gear teeth was simulated by 3-dimensional FEM model. The rolling tool was designed for simultaneous rolling process in which the tooth flank and the fillet at the root of gears could be burnished in one pass. The concave tooth profile of the modified tool was expressed by 3 straight lines approximation. Rolling experiments were conducted using the modified tool optimized in the analysis. The simulation results agreed well with the experimental ones. Gears with a good involute tooth profile were obtained through the rolling processes for 3 kinds of P/M gears in the wide range of depth of tool indentation from 450 to 600 μm.
