Analysis of forming error during thread and spline synchronous rolling process based on motion characteristic

The thread meshing and the spline/gear meshing are intercoupling during thread and spline synchronous rolling (TSSR) process. The subtle difference between different meshing types will lead to profile error of workpiece. Exploring the influence of motion characteristic on the forming error during TSSR process is important for control of pitch error, design of profile compensation of rolling die, and improvement of rolling quality. Thus, in this paper, the accumulative pitch error for spline section of workpiece during TSSR process was defined and modeled according to the motion characteristic in the synchronous rolling process. A quantitative calculating program of the accumulative pitch error has been compiled by using MATLAB code based on the motion models during thread rolling process and spline rolling process. Then, the influences of calculation step, rotating parameter of rolling die at initial contact state, and initial values for numerical solution of motion models of thread section on the calculation accuracy were investigated. The influences of processing parameters and geometrical parameters on the accumulative pitch error were studied by means of orthogonal experiment design method.