Abstract
This paper describes the new method of finish roll forming, where the forced displacement is kept in some prescribed amount during processing. The tooth profiles and the tooth deflection before and after finish are measured for the hobbed spur gears, module 5, made of 0.45% carbon steel having JIS quality class 0 to 4. For finishing the optimal finish condition, various characteristics of the finish, such as maximum deformation on tooth profiles, concave error, displacement at tooth tip, pressure angle error and plastic deflection are illustrated and analyzed. The improvement of profile accuracy by the optimal finishing condition are examined for several types of profile error by theoretical analysis. For example if tooth profiles have pressure angle error in positive or negative value and the accuracy of tooth profiles before rolling is lower than JIS quality class 1, this new method will improve the finishing accuracy by JIS quality class difference 1-2.
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