Abstract:

By taking into consideration the special requirements for function and property of flexspline,the traditional cold rolling process model is analyzed and optimized based on the double-circle-arc model for flexspline.Then,a finite element model describing the cold rolling process is established according to the modified Johnson- Cook constitutive model and is finally verified.Simulated results show that,with the help of the established model,clear double-circle-arc tooth profile and uniform equivalent strain distribution can both be obtained.Moreover,by analyzing the influences of such parameters as feed rate,roller's rotation rate and friction coefficient on the residual stress distribution on gear tooth surface,it is found that ( 1) increasing the feed rate may reduce the maximum residual stress on tooth surface,but excessive feed rate may result in“bulge”on the surface; ( 2) properly reducing the rotation speed and feed rate of the roller may improve the uniformity of residual stress distribution; and ( 3) the friction coefficient positively correlates with the distribution depth of residual compressive stress.

Key words: flexspline, cold-rolling process model, numerical simulation, residual stress, process parameter