Abstract
In this paper, forging of helical gears has been investigated. The forging process of helical gears has been classified into two types of operations: guiding and clamping. The two types of forging of helical gears have been analyzed by using the upper-bound method. Kinematically admissible velocity fields have been developed in which an involute curve has been introduced to represent the tooth profile of the gear. Numerical calculations have been carried out to investigate the effects of various parameters such as module, number of teeth, helix angle and friction factors on the forging of helical gears. Some forging experiments were carried out with commercial aluminum alloy to show the validity of the analysis. Good agreements were found between the predicted values of the forging load and those obtained from the experimental results.
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