Effects of the material and its temperature state on the tooth morphology in gear rolling

The “rabbit ear” defect in gear rolling is closely related with the flow state of the metal in local area. The material of the blank and its temperature state affect the flow state of the metal directly, thus affecting the tooth morphology. In this paper, the quantitative evaluation index of the tooth morphology in gear rolling is established. Through the numerical simulation, the change law of the tooth morphology with different materials such as carbon steel, pure aluminum, and wrought aluminum and that with different forming temperatures are acquired and the reasons are analyzed. Using self-developed gear rolling experiment device, the experiment study of gear rolling is done while pure aluminum, Al_2017, and lead are selected as the material of the blank; the simulation results are verified experimentally. The results provide a scientific basis for the choice of the blank’s material and the forming temperature, controlling the rabbit ear defect and improving the forming quality of gear rolling.