Gear rolling process is a continuous rolling process by rotating and radial feeding motion of rolling wheel. It has advantages of low manufacturing cost, high gear strength and low forming load. The rolling processes of extrusion forming, gear splitting, continuous rolling and reshaping were analyzed by finite element method. The kinematic relationship between the rolling wheel and the forming gear during rolling deformation was studied. The results showed that the meshing motion between the rolling wheel and the billet could be guaranteed when the initial extrusion of the billet was not less than 1 mm. At the rolling gear splitting stage, the equivalent strain of the billet was shown to be related to the deformation of the material, which attained the largest at the root of the tooth. However, the equivalent stress of the billet was found to be dependent on the contact position of the rolling wheel, which has the maximum value at the root of the tooth in the contact area. During the continuous rolling forming stage, the forming load varied regularly and increased continuously with the rolling feed. The tooth profile of the gear was complete after the rolling reshaping process. According to the analysis and calculation results, the structure of rolling forming device was designed. Experiments showed that spiral bevel gears were able to be formed by rolling, and the billet size had an effect on the rolling process. When the size of billet was about 2 mm larger than the dividing circle radius of target gear, the quality of rolled gear was better. The results have important guiding significance for further research rules of rolling forming processes.

齿轮滚压过程是通过滚轮的旋转和径向进给运动进行的连续滚压过程。具有制造成本低、齿轮强度高、成形负荷低等优点。采用有限元方法对挤压成形、分齿、连轧和整形的轧制过程进行了分析。研究了滚压变形过程中滚压轮与成形齿轮的运动学关系。结果表明，当坯料的初始挤压量不小于1mm时，轧制轮与坯料的啮合运动可以得到保证。在轧制齿轮分裂阶段，钢坯的等效应变与材料的变形有关，在齿根处达到最大。然而，发现钢坯的等效应力取决于滚轮的接触位置，在接触区域的齿根处具有最大值。在连续轧制成形阶段，成形载荷有规律地变化，并随着轧制进给量不断增加。经过滚压整形后，齿轮齿形完成。根据分析计算结果，设计了滚压成形装置的结构。实验表明，螺旋锥齿轮可以通过滚压成型，坯料尺寸对滚压工艺有影响。当坯料尺寸比目标齿轮分度圆半径大2mm左右时，轧制齿轮的质量较好。