Abstract
Forming is a metalworking process, where the part undergoes mechanical deformation. It is reshaped without adding or removing any of the material. Cold forming is a process carried out at a temperature below the recrystallization of the alloy. For most metals and alloys this is at room temperature. Cold forming results in enhanced properties and sometimes more economical and also results in better yield compared to machining processes. Orbital cold forming is a niche process for producing net-shaped components. This process has been developed mainly for automotive transmission components in India. It is also desirable to develop nonferrous material like aluminum components using this process and study the advantages and disadvantages. Orbital Forming is a cold-forming process in which a billet / Preformed blank placed on the bottom die is pressed against an upper die which is in orbital motion. The components produced through orbital forming leads to get high dimensional accuracy with high Process capability. In this project, we have a cold-forged Aluminum 6061 billet to produce bevel gear by Orbital Cold forging process, during this process we have done several trials to optimize the force required for the forging process and its Optimum force for Aluminum 6061 and compared it with the steel alloy. Also, a study has been taken for mechanical properties like hardness, tensile strength and strength to weight ratio.
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