Study on the improvements of incremental rolling process for spline shaft with round tools based on finite element method

In order to solve the probable process defects such as uneven tooth forming, disorderly teeth and folded tooth material of the traditional incremental rolling process for spline shaft with round tools, an improved power-type incremental rolling process for spline shaft is proposed, and its feasibility is validated. Furthermore, the improvement of tooth divided flow method (TDFM) is raised to eliminate the negative effects of large rolling blank diameter on the tooth filled quality, especially the second maximum rolling load during the calibrating rolling phase could be avoided effectively. Finally, the improvement of temperature effect is investigated, the tooth filled quality could be enhanced and the rolling load could be declined evidently.