Journal of Materials Processing Technology 234 (2016) 280289

Contents lists available at ScienceDirect

Journal of Materials Processing Technology

journal homepage: www.elsevier.com/locate/jmatprotec

Numerical simulation and experimental study of slippage in gear

rolling
Jin Li, Guangchun Wang , Tao Wu
Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials of Ministry of Education,Shandong University, Jinan 250061,China

a r t i c l e

i n f o

Article history:
Received 29 September 2015
Received in revised form 29 March 2016
Accepted 31 March 2016
Available online 1 April 2016
Keywords:
Gear rolling
Slippage
Finite element analysis

a b s t r a c t
Gear rolling has the advantage of efcient material application, contour-related ber orientation, and
can overcome forming difculties of gear forging. In the initial stage of gear rolling, often the slipping
phenomenon occurs. Slippage and the degree of slippage signicantly affect the forming quality of the
tooth shape. In this paper, the applied forces on a blank in the initial forming phase of the gear rolling were
analyzed, and the main factors affecting slippage were determined. Then, the quantitative evaluation
index of the slippage was established. The effect of initial bite depth, friction condition, and number of
teeth on the gear roller on slippage was obtained using nite element analysis. The effect of different
initial bite depths and number of teeth on the gear roller on the slippage was studied experimentally.
Moreover, the reliability of the nite element simulation results of gear rolling was veried. The results
can provide a scientic basis for establishing reasonable process parameters, control of slippage, and
improving the forming quality in gear rolling.
2016 Elsevier B.V. All rights reserved.

1. Introduction
Compared to the metal-removing production processes, forming gears have many advantages. Besides a high degree of material
utilization and short process times, forming technology has the
advantage of adapted ber orientation, which endows a gear with
better mechanical properties. Since the 1960s, studies have been
conducted on the forging technology of cylindrical gears. The
material divided ow method was the most accepted method of
cylindrical gear production as it decreased the forming force and
allowed the oating die to improve the lling of tooth prole. Kondo
and Ohga (1995) used the divided ow principle for the cold precision forging of spur gears. Tuncer and Dean (1987) examined 18
die design alternatives for the precision forming of hollow parts
to conrm their predicted performance by forging tests on some
designs. Tuncer and Dean (1988) outlined the general problems
and requirements of dies for ashless forging, presented alternative designs, and described various hollow shapes, which have been
precision forged from hollow billets. Choi and Choi (1999) studied
the gear precision forging process by the two-step divided ow
molding method. Kou et al. (2000) proposed a constrained divided
ow and two step forming of spur gear cold forging. Although the

Corresponding author.
E-mail address: wgc@sdu.edu.cn (G. Wang).
http://dx.doi.org/10.1016/j.jmatprotec.2016.03.030
0924-0136/ 2016 Elsevier B.V. All rights reserved.

proposed methods by the above studies have reduced the forming force, the gear forging process in replacing the metal-removing
production processes still leads to many problems for dies such
as large elastic deformation affecting tooth surface precision and
difcult withdrawal from the die because of a larger load.
To address the technical problems present in the application
of precision cylindrical gear forging, the gear rolling process is proposed for consideration. The gear rolling process has the advantages
of gear forging, and at the same time, the gear rolling process can
overcome the forming difculties of gear forging such as the incomplete lling of the tooth corner, difcult withdrawal from the die,
and the low service life of dies. Due to these advantages, this new
forming process has good prospects.
The forming principle of gear rolling is shown in Fig. 1, where a
pair or more of gear rollers with the same parameters rotate synchronously in the same direction and extrude the blank along the
radial axis simultaneously, so that the outer metal of the blank
gradually forms a tooth prole. In the initial stage of gear rolling,
the bite depth that the gear roller teeth press into the blank is
shallow. Because of the shallow depth, slippage occurs easily on
the contact surface between the gear roller and the blank, resulting in disordered/staggered/multi-teeth, which severely affects the
forming quality of the gear.
Gear rolling has been studied in the recent years in advanced
cold precision forging technology, but has been rarely reported
as much research is hidden by industry. Neugebauer et al. (2007)

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

281

to rotate. Liu (2009) also reported the rotating conditions through

studies on tooth graduation in spline-shaft cold rolling.
In this paper, the applied forces on the blank and the inuencing factors on its rotation in the initial forming phase of gear rolling
were analyzed to obtain the main factors affecting slippage. A quantitative evaluation index of slippage was established. The nite
element model of gear rolling was used, and the tooth graduation
process in the initial forming stage of gear rolling was simulated.
The experimental results were analyzed to evaluate the effect of the
initial bite depth and number of teeth on the gear roller on slippage.

2. Analysis of applied forces, and inuencing factors on

gear rolling slippage
Fig. 1. Schematic diagram of gear rolling.

described the rolling process and an alternative pitch design of

forming tools. Kamouneh et al. (2007a,b) investigated the work
hardening of at-rolled helical-involute gears through grain-ow
analysis, FE-modeling, and strain signature. Uematsu (2002) studied the effect of the variation of angular velocity in gear rolling
process on prole error. Although papers and patents related to
the abovementioned gear rolling have been published, no relevant
study has been reported on the slippage in gear rolling. Research
about rolling slippage concentrated more on spline cold rolling.
Zhao et al. (2009) analyzed the relative sliding between the gear
roller and blank in spline rolling and drew conclusions that the
larger the friction coefcient, the greater the ratio of the diameter
of the gear roller to the blank, and the more conducive the blank is

In the initial phase of the gear rolling process, when the gear
rollers contact the blanks outer circumference surface, the forces
which rotate the blank are primarily from the contact portion of the
gear rollers addendum and blank. At the moment when the rst
tooth of the gear roller on the horizontal axis contacts the blanks
outer circumference surface (Fig. 2(a)), the blank can rotate with the
gear roller if the tangential friction force F, generated from radial
force N, overcomes the rotating resistance applied by the blanks
clamping shaft and its own inertial force. The force vectors between
the gear roller and blank are shown in Fig. 2(b). This indicates that
the gear roller begins to bite into the blank at an increased depth.
At this point, the next tooth gradually bites in, and the exiting tooth
gradually slides out. Rolling forces are mainly applied by the tooth
which penetrates into the blank; these forces are divided into three
parts: normal force N1 , friction force f1 , and tangential force F1 . The
forces applied by the exiting tooth mainly include the tangential
force F0 and friction f0 .

Fig. 2. Applied force on the blank. (a) When the gear roller initially contacts the blank. (b) When the gear roller bites into the blank at a depth.

Fig. 3. Finite element simulation model.

282

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

Table 1
Basic parameters of gear rolling in FEM model.
Basic parameters

Number of teeth on the

gear to be formed

Number of teeth on the gear roller

Friction factor

Blank material

Forming temperature

Blank grid

Value

31

51

0.7

AL 1100

20 C

180,000

Fig. 4. Diagram of the point tracking. (a) At the beginning of rolling. (b) After rolling half a circle. (c) Enlarged view indicating slippage had occurred.

The applied force was analyzed in the initial phase of the gear
rolling process. When the gear roller and blank contacts, it is shown
that the effect of the friction between the two surfaces is dominant.
When the gear roller bites into the blank at a depth, in order for the
blank to rotate, the torque generated by both the tangential force
(F0 , F1) and friction (f0 , f1 ) must overcome the resistant moment of
the radial force (N1 ).
The applied force analysis shown in Fig. 2 indicates that when
the gear roller penetrates into the blank, the push forces which
drive the blank rotation mainly originate from the friction and the
tangential force that the tooth ank of the gear roller applies on the
blank. The friction is related to the friction factor of the gear roller
and blank. The tangential force is related to the gear rollers bite
depth. The number of teeth on the gear roller affects the angular
dimension  shown in Fig. 2; it also affects the resisting moments
arm length shown in Fig. 2. It has been determined that the main
factors inuencing the blank rotation include the initial bite depth,
the friction factor, and the number of teeth on the gear roller.

Fig. 5. Change in slippage with varying time step sizes.

3. Evaluation index of slippage

Slippage signicantly affects the forming quality of the tooth
shape on the blank; therefore, it is necessary to establish an evaluation index of slippage that can be used to determine and evaluate
slippage under different conditions.
Slippage can be dened as the difference between the angle that
the blank rotates followed the gear roller with slipping and without
slipping, i.e.,
= ns s

(1)

In Eq. (1), ns is the angle that the blank rotates followed the gear
roller without slipping, and s is the angle that the blank rotates
followed the gear roller with slipping.
4. Simulation and analysis of slippage in gear rolling
Deform3D software was used to simulate the split-tooth forming process in the initial stage of gear rolling. The basic parameters
and environmental variables of the model are shown in Table 1.
The specic settings were as follows: the gear to be formed and the

Fig. 6. Change in slippage with varying initial bite depth.

gear rollers were standard, both the modulus were set as 1; both
the pressure angles were 20 ; the thickness of the blank was 2 mm.
He (2001) proposed that the chord length of the blank is equal to
that of the gear roller between two teeth. Based on this theory, the
diameter of the blank was calculated as a guarantee of proper tooth
graduation. As the radial constraint cannot be set in deform, a hole
diameter of 5 mm was set in the center of the blank, with a rigid
shaft of the same size placed in it to set the radial constraint. The

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

283

Fig. 7. Slip distinction from different bite depth (a) shallow bite (b) deep bite.

Fig. 8. Geometric relationship of the gear roller and blank. (a) Diagram of equal chord length. (b) Gear roller bites into the blank.

Fig. 9. Changes in slippage with varying friction factor.

Fig. 10. Changes in slippage with varying number of teeth on the gear roller.

friction factor of the rigid shaft and blank were set as 0 to ensure
that the blank rotated around the rigid shaft without friction in the
rolling process.
To prevent the diameter of the blanks center hole from getting
larger, the blank was made as a step with a diameter of 15 mm and a
thickness of 16 mm. Because the blanks deformation along the axial
direction is symmetrical during rolling, a half thickness was simulated to improve the efciency of the simulation; the end surface
was set to a symmetry constraint. A shearing friction model was set,
and the friction factor in the range 01 was used. Because the blank
rotation was driven by the gear roller from a rotary forming process such as gear rolling and cross wedge rolling, the friction factor
was set as a larger value. The blank material was set as aluminum,

which is relatively soft and similar to steels hot state; therefore, the
maximum friction factor was set to 0.9. Only the material of the
blanks outer ring was rolled in the initial forming phase. Therefore, the local mesh of the 0.5 mm thick annular region of the blanks
outer ring was rened, and the mesh density ratio 0.01 was used.
Because of the effect of stress on the contact area of the blank and
the center shaft, the local mesh of the 0.5 mm thick annular region
of the blank which contacts the shaft was rened, and the mesh
density ratio was also set to 0.01. Both the gear rollers were rigid,
and their geometric relationship is shown in Fig. 3.
To obtain the blanks actual rotating angle in the simulation, the
point tracking method was used. At the beginning of the simulation, a point P1, was selected along the horizontal axis on the blank

284

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

Fig. 11. Applied force analysis of the blank on different numbers of teeth on the gear roller.

Fig. 12. Gear rolling device and rolled blanks. (a) Device schematic diagram. (b) Experimental apparatus. (c) Enlarged view. (d) Experimental rolled blanks.

surface as shown in Fig. 4(a). Because the gear roller rotates at a

constant speed in the simulation, the time of the gear roller rolling
N teeth can be calculated. The coordinate of P1 point can be determined when the gear roller rolls N teeth using the point tracking
method as shown in Fig. 4(b). The angle of P1 point can be obtained
by calculation; thus, the blanks actual rotating angle can be calculated when the gear roller rolls N teeth. The simulation results
indicate that after rolling half a circle, severe slipping had occurred
as shown in Fig. 4(c).

Table 2
Simulated slippage while rolling half a circle under different time step sizes.
Time step size (1e-05s)
Total slippage ( )

0.3
1.70

1
1.78

3
1.95

6
2.34

10
3.42

30
7.05

In the numerical simulation, the time step size signicantly

affected the simulation results. To select appropriate time step size,
rst, the effect of time step size on the slippage in the simulation

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

285

Table 3
Gear rolling simulation parameter matrix.
Simulation scheme

Initial bite depth (mm)

Friction factor

Number of teeth on the gear roller

1
2
3

0.15/0.20/0.25/0.30
0.15
0.15

0.7
0.6/0.7/0.8/0.9
0.7

51
51
37/51/75/95

Table 4
Simulated slippage while rolling half a circle under different initial bite depths
(Scheme 1).
Initial bite depth (mm)
Total slippage ( )

Fig. 13. Staggered and normal tooth region.

was analyzed. Based on satisfying the basic conditions that the arc
length of the gear roller rotating is smaller than 1/3 of the minimum
mesh-length in the blank during each time step size, the step size of
3e-06s, 1e-05s, 3e-05s, 6e-05s, 1e-04s, and 3e-04s were set in the
simulation. The basic parameters of the simulation are shown in
Table 1, and the initial bite depth was 0.15 mm. The total angle
of slippage was used as a metric, determined across the period
required for the two gear rollers to roll half a circle on the blank,
i.e., 15 teeth. The simulation results are shown in Table 2. The total
slippage as a function of step size from Table 2 is shown in Fig. 5.
As shown in Fig. 5, with the decrease in the time step size, the total
slippage decreased. Moreover, when the time step size of 3e-05s
and less were selected, the decreasing trend of slippage slowed
down to almost a horizontal curve, indicating that the amount of
slippage became a constant, and no longer decreases. Gabriel and
Bathe (1995) proposed the solution converges as the time step size
is reduced for large deformation elastic-plastic analysis, illustrated
the solution using the trapezoidal integration scheme has better

0.15
1.95

0.20
1.54

0.25
1.36

0.30
1.02

accuracy characteristics than using the Euler backward. However,

the solution using the trapezoidal integration scheme should be
restricted to employ a maximum step size which is given by an
accuracy criterion that the plastic strain increments are of the same
order as the total elastic strains. Zhang et al. (2004) analyzed the
effect of the step size on the load in the numerical simulation on
precision forging of spur gears, indicated that the bigger the step
size, the bigger deviation of the load. Cemil and Tekkaya (1996)
selected the smaller step size in order to improve the precision
of the simulation in the study of quenching process. Based on the
above, considering the accuracy of simulation and the hardware
conguration of the computer, the time step size of the following
simulation was set as 3e-05s.
The slippage during the initial state of gear rolling was investigated further to understand the effects of factors including the
initial bite depth, set friction factor, and the number of teeth on the
gear roller. The simulation schemes with different parameters are
shown in Table 3. The total angle of slippage was used as a metric,
determined across the period required for the two gear rollers to
roll half a circle on the blank, i.e., 15 teeth.
4.1. Initial bite depth
In simulation Scheme 1, the initial bite depths of 0.15 mm,
0.20 mm, 0.25 mm, and 0.30 mm were set, with a gear roller tooth
number of 51. The rotation speed of the gear roller was 5 rad/s. The
friction factor was 0.7. The simulation results are shown in Table 4.
The total slippage as a function of bite depth from Table 4 is shown
in Fig. 6.
As shown in Fig. 6, with the increase in the initial bite depth,
the total slippage decreased. This is because when the bite depth
was smaller, the tangential force that the gear roller exerted on

Fig. 14. Rolled blanks of different bite depth. (a) Bite depth 0.15 mm. (b) Bite depth 0.20 mm. (c) Bite depth 0.25 mm. (d) Bite depth 0.30 mm.

286

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

Fig. 15. Indentations of the rolled blanks. (a) Bite depth 0.15 mm. (b) Bite depth 0.20 mm. (c) Bite depth 0.25 mm. (d) Bite depth 0.30 mm.

Table 5
The slippage when rolling half a circle under different friction factors (Scheme 2).
Friction factor
Total slippage ( )

0.60
2.02

0.70
1.95

0.80
1.68

0.90
1.64

Table 6
Slippage when rolling half a circle under varying number of teeth on the gear roller
(Scheme 3).
Number of teeth on the gear roller
Total slippage ( )

37
2.43

51
1.95

75
1.70

95
1.66

the blank to overcome rotation resistance caused the plastic deformation of the material of the contact area of the gear roller and
the blank. This attened the pit, leading to a larger slip as shown in
Fig. 7(a). With the deeper initial bite depth, the penetration into the
blank was correspondingly deeper, thus allowing the tooth that has
bitten the blank to apply thrust more easily on the pit sidewall in
the same direction as the blank rotation. This means that the blank
rotates more easily, and the slippage is smaller as shown in Fig. 7(b).
To ensure proper tooth graduation, the diameter of the blank was
set according to the principle of equal chord length as shown in
Fig. 8(a). When the gear roller bites into the blank as shown in
Fig. 8(b), the blanks valid arc length ensuring proper tooth graduation decreased, i.e., the blanks valid arc length is not enough for
tooth graduation. This can offset some amount of slippage. Based
on the above description, along with the increase in the initial bite
depth, the total slippage decreased.

Fig. 16. Slippage with varying initial bite depths from experimental results.

simulation results are shown in Table 5. The slippage as a function

of friction factor from Table 5 is shown in Fig. 9.
As shown in Fig. 9, with the increase in the friction factor, the
total slippage decreased. When the other conditions were the same,
the greater the friction factor was, the greater the friction between
the gear rollers addendum and the blank was. By using applied
force analysis in the initial stage of gear rolling in the last section,
it was observed that the friction force contributes to the blanks
rotation, and the direction of the friction force is the same as that
of the rotation. Therefore, with the increase in the friction factor,
both the friction force and friction torque increased. Thus, it is easy
to overcome the resistance torque, and the blank is easy to rotate
so that the total slippage decreased.

4.2. Friction factor

4.3. Number of teeth on the gear roller
In Scheme 2 as shown in Table 2, the friction factors were set as
0.60, 0.70, 0.80, and 0.90 for the simulation analysis. The rotation
speed of the gear roller was set as 5 rad/s, and the number of teeth
on the gear roller was 51. The initial bite depth was 0.15 mm. The

The tooth numbers of the gear roller were selected as 37, 51, 75,
and 95. The rotation speed of the gear roller was 5 rad/s. The friction
factor was 0.7. The initial bite depth was 0.15 mm. The simulation

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

287

Fig. 17. Rolled blanks of varying number of teeth on the gear roller (a) 37, (b) 51, (c) 75, and (d) 95.

Table 7
The calculated total slippage of the rolled blanks from experimental results of the bite depth.
Initial bite depth (mm)
Indentations wide difference (mm)
Slippage ( )
Average slippage  ( )

0.15
0.64
2.26
2.26

0.69
2.44

0.59
2.1

0.20
0.39
1.4
1.28

0.29
1.04

0.39
1.4

0.25
0.29
1.04
0.94

0.24
0.88

0.24
0.88

0.30
0.10
0.36
0.40

0.15
0.54

0.12
0.42

Table 8
Calculated total slippage of the rolled blanks from experiment of varying number of teeth on the gear roller.
Varying number of teeth on the gear roller
Indentations wide difference (mm)
Slippage ( )
Average slippage  ( )

37
0.74
2.56
2.84

0.83
2.92

0.88
3.08

51
0.64
2.26
2.26

results are shown in Table 6. The slippage as a function of number

of teeth on the gear roller is shown in Fig. 10.
As shown in Fig. 10, with the increase in the number of teeth
on the gear roller, the total slippage decreased. The applied force
analysis determined that along with the increase in the number
of teeth on the gear roller, the arm L of resistant moment, which
is produced by the thrust of N, decreased gradually as shown in
Fig. 11. This in turn led to a decrease in resistant moment, thus
allowing the blank to rotate more easily and decreasing slippage.
Moreover, with the increase in the number of teeth on the gear
roller, the contact area of the gear roller and the blank increased,
which also decreased the slippage.

0.69
2.44

0.59
2.1

75
0.54
1.94
1.88

0.54
1.94

0.49
1.76

95
0.44
1.60
1.54

0.44
1.60

0.39
1.42

rollers were used to roll a little more than half a circle of the blank
to study the staggered teeth region.
The Experimental results show that in the second rolling region,
the second indentation did not exactly coincide with the rst, leading to staggered teeth. As shown in Fig. 13, in the staggered tooth
region, the second indentation overlapped the rst, making the
indentations wider. The indentation feature is too small to measure
easily; therefore, by applying paint to the surface of the staggered
teeth and rolling an imprint onto paper, it was possible to record
the width along the circumferential direction. The slippage was calculated by measuring the width differences between the staggered
and normal tooth.
5.1. Experiments of initial bite depth

5. Experimental verication and analysis of results

According to the basic principle of gear rolling, a set of experimental apparatus was designed and fabricated as shown in Fig. 12.
According to the above simulation results, the change in slippage
with varying initial bite depth was the largest, the change in slippage with varying number of teeth on the gear roller is the second,
and the change in slippage with varying friction factor is the least.
The slippage is not sensitive to the change in friction factor. Thus,
experiments of different initial bite depths and number of teeth on
the gear roller affecting the slippage were carried out under similar parameter conditions as the previous simulations. The specic
experimental conditions were as follows: the number of teeth on
the gear to be formed and the gear roller were 31 and 51, respectively; both the modulus were 1; the pressure angles were both
20 ; the material of the blank was pure aluminum with a thickness
of 2 mm; the motors rotation speed was 50 rpm, consistent with
the simulation; and the initial bite depths were 0.15 mm. Two gear

Scheme 1 shows the initial bite depths to be 0.15 mm, 0.20 mm,
0.25 mm, and 0.30 mm. Fig. 14 shows the four sets of blanks produced from the different initial bite depths as per above.
Three rolled blanks of the same bite depth were measured as
shown in Fig. 15. The measured and calculated results, as well
as their average value are shown in Table 7. The experimentally
observed slippage as a function of initial bite depth from Table 7 is
shown in Fig. 16.
The comparison between Figs. 16 and 6 shows that the slippage
in experiment is consistent with that in simulation, decreasing with
increasing initial bite depth.
5.2. Experiments of the number of teeth on gear roller
Scheme 3 shows the number of teeth on the gear roller to be 37,
51, 75, and 95. Fig. 17 shows the four sets of blanks produced from
varying number of teeth on the gear roller as per above.

288

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

Fig. 18. Indentations of the rolled blanks. (a) Number of teeth 37. (b) Number of teeth 51. (c) Number of teeth 75. (d) Number of teeth 95.

understanding and model of slippage during the initial phase of

gear rolling.
6. Conclusions
In this study, a metric of slippage, as a function of various
rotational movement related factors, was calculated from several
simulation schemes. Using the numerical simulation and experimental study, the effect of the main process factors on the slippage
in the initial forming phase of gear rolling was observed.

Fig. 19. Slippage with varying number of teeth on the gear roller from experimental
results.

Three rolled blanks of the same number of teeth on the gear

roller were measured as shown in Fig. 18. The measured and calculated results as well as their average values are shown in Table 8.
The experimentally observed slippage as a function of number of
teeth on the gear roller from Table 8 is shown in Fig. 19.
The comparison between Figs. 19 and 10 shows that the slippage
in experiment is consistent with that in simulation, decreasing with
increasing number of teeth on the gear roller.
The slippage determined from experimental results was not
completely consistent with that of the simulation. This was probably because the accuracy of the experimental apparatus was
limited, inertia from the blank could not be applied in the simulations, and the friction condition in the experiment may be not
consistent with that of the simulation. These results are positive in directing further research to fully develop a more capable

(1) According to the applied force analysis between the gear roller
and blank in the initial phase of gear rolling, the main factors
affecting the slippage were determined to include the initial
bite depth, friction conditions, and the number of teeth on the
gear roller.
(2) The effects on slippage were obtained from numerical simulation results. The slippage decreased with increased initial bite
depth, friction factor, and number of teeth on the gear roller.
(3) The experimental results of different initial bite depths showed
that the slippage decreased with increased initial bite depth and
decreased with increased number of teeth on the gear roller,
consistent with the simulations.
Acknowledgements
This project was supported by the National Natural Science
Foundation of China (Grant No. 51475271).
References
Cemil, H.G., Tekkaya, A.E., 1996. Finite element simulation of quench hardening.
Steel Res. 67, 298306.

J. Li et al. / Journal of Materials Processing Technology 234 (2016) 280289

Choi, J.C., Choi, Y., 1999. Precision forging of spur gears with inside relief. Int. J.
Mach. Tools Manuf. 39, 15751588.
Gabriel, G., Bathe, K.J., 1995. Some computational issues in large strain
elasto-plastic analysis. Comput. Struct. 56, 249267.
He, F., 2001. Design of cold rolling tools for small module involute spline shafts.
Tool Eng. 35, 2325.
Kamouneh, A.A., Ni, J., Stephenson, D., Vriesen, R., DeGrace, G., 2007a. Diagnosis of
involute metric issues in at rolling of external helical gears through the use of
nite-element models. Int. J. Mach. Tools Manuf., 12571262.
Kamouneha, A.A., Ni, J., Stephenson, D., Vriesen, R., 2007b. Investigation of work
hardening of at-rolled helical-involute gears through grain-ow analysis,
FE-modeling, and strain signature. Int. J. Mach. Tools Manuf., 12851291.
Kondo, K., Ohga, K., 1995. Precision cold die forging of a ring gear by divided ow
method. Int. J. Mach. Tools Manuf. 35, 11051113.
Kou, S.Q., Yang, S.H., Huang, L.J., Fu, P.F., 2000. The applications of constrained
divided-ow technique to cold precision forging spur gears. Nat. Sci. J. Jilin
Univ. Technol. 30, 1923.

289

Liu, Z.Q., 2009. Qualication of tooth graduation for cold-rolling formation of

spline. J. Lanzhou Univ. Technol. 35, 3538.
Neugebauer, R., Putz, M., Hellfritzsch, U., 2007. Improved process design and
quality for gear manufacturing with at and round rolling. CIRP Annals-Manuf.
Technol. 56, 307312.
Tuncer, C., Dean, T.A., 1987. Die design alternatives for precision forging hollow
parts. Int. J. Mach. Tools Manuf. 27, 6576.
Tuncer, C., Dean, T.A., 1988. Precision forging hollow parts in novel dies. J. Mech.
Work. Technol. 16, 3950.
Uematsu, S., 2002. Effect of variation of angular velocity in gear rolling process on
prole error. J. Int. Soc. Precis. Eng. Nanotechnol. 26, 425429.
Zhang, Q.P., Shang, Y., Zhao, G.Q., Luan, Y.G., 2004. Numerical simulation of analysis
parameters in precision forging of spur gears. China Mech. Eng. 15, 15461548.
Zhao, Y.M., Wang, J.L., Liu, J., 2009. Numerical simulation of incremental cold
rolling for spline tube with two rollers. Hot Work. Technol. 38, 7375.