The application of fine blanking to the manufacturing of helical gears directly from a strip has been restricted due to the traditional linear cutting stroke of the punch and die. In this work, rotational fine blanking which combined the linear and rotational motion of punch and counterpunch was applied for the forming of helical gears. A three-dimensional (3D) rigid-plastic finite element model was developed on the DEFORM-3D platform. By finite element simulation and analysis, the influences of key parameters on the punch load and cut surface were investigated. It is shown that:1) with increasing the counterforce or helical angle, the punch load and the depth of die roll increase;2) with increasing blank holder force, the punch load increases while the depth of die roll decreases;3) V-ring indenter facilitates an improvement in the quality. The results of this research reveal the deformation mechanism of rotational fine blanking of helical gears, and provide valuable guidelines for further experimental studies.
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