DEVELOPMENT OF A SOFTWARE PACKAGE FOR THE MANUFACTURE OF INVOLUTE SPLINE ROLLING DIES

DEVELOPMENT OF A SOFTWARE PACKAGE FOR THE MANUFACTURE OF INVOLUTE SPLINE ROLLING DIES

ABSTRACT:
A software package for designing circular incremental rolling dies for producing involute splines and serrations and for generation of punched tape for machining the same on CNC wire cut EDM has been developed. The paper describes the design concepts and various modules of the software developed.

INTRODUCTION:
Cold rolling process is extensively used in the large volume production of involute splines and serrations on components used in automobile industries. Rolling could be accomplished by tangential flat rolling dies or circular dies. In the incremental process using circular rolls, the job is fed between two rolls and the rolling is completed within one revolution of the forming rolls. The forming rolls have an evolutive profile so that the rolling action gradually takes place without altering the center distance between the rolls. The tooth form on the forming rolls will be conjugate with the spline teeth to be produced on the job. However, the forming coils will have a set of penetration teeth to facilitate gradual rolling to full depth, calibration teeth to hold the correct profile on the job and decompression teeth to compensate for any spring back. These rolls are usually produced on a CNC wire cut Electro discharge machine. However, the part programming software has to be specially developed, since this cannot be accomplished with the software provided for general programming of the machine. Even though thread rolling dies is not available and the punched tape for production of the rolls has to be procured from abroad.

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