Abstract

Hot finish rolling has been proposed as a simple finishing process for injection-molded plastic gears. In this process, plastic work gears are finished by meshing with a heated die wheel under very low load. Heat applied by the die wheel yields a melted layer on a tooth flank of the plastic work gear, and sliding between tooth flanks of the die wheel and the work gear induces material flow in the melted layer. This material flow contributes to the change in the work tooth form. Therefore, in order to simulate the hot finish rolling process, the material flow must be analyzed. The present paper describes a simple model in which the material flow is considered as the flow of incompressive fluid with free surface. Then, the effects of the sliding velocity and the friction are discussed. As a result, calculated forms of free surfaces qualitatively agreed with measured forms of finished teeth.

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