Finite element simulation of an analogy process for the fine blanking of helical gears

Fine blanking can today be used for the production of spur gears but not for helical gears. Based on a newly developed process principle for the fine blanking of helical gears, an analogy process was set up and investigated in finite element simulations using the software Deform-3D. For the numerical model, the tool components were assumed rigid, while workpiece behavior was modeled as plastic with isotropic strain hardening. Damage initiation was included by using a normalized formulation of the Cockroft and Latham damage criterion. Results show, that sheet thickness and helix angle are key influence factors for the final workpiece properties as well as for the stress distribution in the workpiece during the process. Their influence varies with respect to the tooth section, i.e. tooth flanks and tooth tip.