Abstract
The purpose of this study is to examine a practical application of a finish rolling process using a screw-shaped tool to consolidate the surface layer of sintered Fe alloy gears and to improve the tooth profile accuracy and the load carrying capacity simultaneously. These objectives are almost attained in the previous works except the crowning in tooth trace direction, which is the essential matter for gears in automotive transmissions. In this paper, a numerical control finish rolling machine is developed to enable the crowning process. In this new apparatus, the amount of radial feed of the tool is synchronized with the axial feed of the workpiece to put a specified crowning on the rolled gear teeth. A simple calculation method is proposed to decide the rolling orbit for crowning. The crowning profiles predicted in the analysis agree well with the experimental ones. Gears with a good tooth profile and a good surface finish can be obtained.
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