Abstract
Gear rolling is a new gear manufacturing process which can partly replace traditional gear milling processes. High gear wheels with modules of 4mm up to 6mm are of interest to truck manufacturing. The process is of interest since it involves no material removal and since it has the potential to give good performance of the gear wheels. The process must be adopted for the large plastic deformations which occur for gear rolling with large modules. In this paper special emphasis will be put to loads and torques during the gear rolling process of gear wheels with large modulus. The FE method will be used to model the plastic deformation process to fully form a gear wheel with the gear rolling method. The radial and axial loads and the torques in this process are predicted. The loads of the process are high compared to the situation for small gear wheels so simulation of load level is essential for the design of rolling machines for high gears.
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