Wear analysis and prediction for oscillating longitudinal gear forming

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Requirements for formed parts as well as cost pressure are steadily increasing at the same time. This requires an increasing flexibility and output in the manufacturing process with simultaneously better quality or availability. One way to increase quality and cost effectiveness of forming processes is the use of adapted and in particular oscillating ram movements. With the use of these ram movements e.g. process limits can be expanded, forming forces can be reduced and the dimensional accuracy of workpieces can be affected. However, the wear behavior is not yet examined using oscillating ram movements. They affect tribological conditions as well as the contact length of tool and workpiece which have to be considered calculating the wear behavior. Initial numerical studies on calculating adhesive wear of forming gears with Archards model show an increase of wear using an oscillating compared to a conventional ram movement. However, this model does not consider tribological conditions. In the proposed research project the effects of oscillating ram movements on the wear behavior will be studied, calculated and predicted. Therefore, adapted wear models of Archard and Rabinowicz are used. With the help of these models it will be investigated whether adhesive and abrasive wear can be predicted for varying tribological conditions and oscillating movements.