A study on the integrated forming mechanism of cross-wedge rolling gear shaft and tooth

To realize high-efficiency and accurate manufacturing of gear shafts in a short process, this paper presents an innovative integrated forming method of cross-wedge rolling gear shafts. Based on an analysis of the principle of tooth profile plastic forming, the main parameters of the processing die were synthesized, obtaining a parameter formula satisfying the condition of tooth separation and the design of the gear shaft cross-wedge rolling die. The stage of the tooth mold entering the machining process was designed using the software Deform, obtaining the best quality of the tooth mold entering the finished product in the first stage of the stepped shaft. On this basis, the simulation was conducted to analyze the stress field, strain field, and temperature field. Then, the forming mechanism of gear-shaft-integrated cross-wedge rolling was clarified. A comparison of simulation and experimental results showed that the error was less than 8. 2%, verifying the reliability of the simulation results. The results of this paper lay a theoretical foundation for the realization of the precise short process forming of gear shaft integration. © 2024 Editorial Board of Journal of Harbin Engineering. All rights reserved.