Influence of friction on the material flow during precision forging of helical gears

Abstract

At the Institute of Metal forming and Metal forming machine tools (IFUM), University of Hannover, helical gearwheels are produced from cylindrical billets using single state precision forging processes. For a process integrated heat treatment, the workpiece materials need to be carburized already before the forming operation. Thus, in contrast to conventional manufacture, an inhomogeneous case depth distribution is obtained resulting from the material flow during forming. A numerical process simulation with the finite element method (FEM) enables to predict this distribution along the shape of the teeth. The performed experimental and numerical investigations illustrate the influence of friction conditions on the material flow and thus its influence on the case depth distribution.