Advanced Material Modelling For Gear Rolling Densification Simulations

Gear rolling densification is a post sintering process in which the porosity is closed at the surface and in some depth into the flank surface of the gear. The rolling process improves the mechanical properties such as the contact strength.

In order to optimize the gear rolling process and produce more accurate results, FE (Finite Element) simulations have been used for validation and thereafter optimization of tool, gear geometry and overall process.

In this paper, FE simulations will be conducted with two plasticity material models to understand theirs behavior in compression and tension. Moreover, experimental results from an indentation of a wrought steel ball to a PM material will be correlated to FE simulation results for different load levels. Furthermore, gear-rolling simulation results will be compared to experimental results for both material models in porosity level and involute profile.