Research on deformation mechanism and load effects of three-roller bending process for large gear teeth profile

Aiming at the problems of a large amount of material cutting waste or large forming load when large gear profile forming adopts overall cutting or precision forging process, this paper proposed a three-roller bending process (TRBP) for large gear teeth profile, and analyzed the deformation mechanism of the rack bending, meanwhile the gear chain for roll forming was designed. Finite element analysis (FEA) was carried out to numerically simulate the load effects of both the precision forging process and the TRBP for the large gear teeth profile in 17CrNiMo6. The effects of deformation force and strain of TRBP for large gear teeth profile were analyzed. The results showed that as the deformation temperature and speed increase, the deformation force and strain required by the gear profile gradually change. And the reasonable parameter of TRBP is around 750 ∘ C of deformation temperature and 0.5 mm · s - 1 of speed. Compared with the precision forging process under the same boundary conditions, the deformation force of the gear profile TRBP has decreased by about 99 % which could significantly reduce the tonnage requirement of deforming equipment.