Numerical simulation and experimental study on multi-pass stagger spinning of internally toothed gear using plate blank

Internally toothed gears have wide application as transmission components, for which spinning process is attracting increasing attention due to its high production efficiency and low cost. In this paper, a multi-pass stagger spinning process of internally toothed gear from plate blank was investigated through FEM simulation and process experiment. Two passes, i.e., drawing spinning and power spinning, were designed during stagger spinning. The deformation characteristics were analyzed, the mechanisms of spinning defects were revealed and the influences of process parameters were discussed. It is shown that the preform formed by drawing spinning in the first pass contributed to the filling of inner tooth cavity in the second pass. Underfilling and crack in the vicinity of the tooth were two typical defects, which could be effectively controlled through optimizing the spinning process. On this basis, the internally toothed gear was well formed with high productivity by stagger spinning on a CNC spinning machine, showing great potential for industrial application.