Resources are getting shorter, so that the cost structure shifts to higher amounts of material and energy costs. Because of that, near net shape technologies become more competitive. PM gear rolling which is one of those near net shape technologies is a complex technology for a component with high requirements on mechanical properties and shape tolerances. Compared to established technologies such as gear hobbing, the application of gear rolling is challenging for part makers, as the effort needed for process development and prototype manufacturing is not predictable. The interaction of experience in tool manufacturing, a CNC controlled rolling machine and CNC controlled gear measuring centre together with a process simulation is necessary for a sufficient implementation of gear rolling in the process chain. This paper shows how a high quality gear can be produced with a precise machine, a high densification and a modified tool. Based on rolling experiments deviations and the densification are analyzed. With these results the tool is modified in order to compensate the deviations and the stock for material is adjusted. Rolling trials follow to optimize the stock for densification and tool modifications and to define suitable process settings in terms of process time and profile quality. The results of the rolling trials are evaluated, the final tool modifications and stock for material are designed.
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