Cold rolling process is widely used in production of the involute spline. The traditional process is lack of systemic and instructional theory. The production often depends on the experts' experience. In this paper, a cold rolling slip-line field graphic model is established by analyzing the theory and mechanics during the process of external spline cold rolling according to assumptions. Using this mathematical model, the cold process is analyzed accurately by the effect of profile error of spline cold rolling to variety of tooth surface contact number and discovered the cause of error according to constant volume principle. Experiment results demonstrate that the rolling stress plays the role of modification of the tooth tip and root. And the prominent bumps in the middle of tooth profile occur. The carrying capacity and smooth operation accordingly increase.
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