Manufacture of face gearing – a new production method by means of determined material pre-distribution

Abstract

Research subject of this paper concerns the manufacturing of face gearing on hollow shafts. Currently, the toothing is produced by a coining process. This results in high process forces which strongly restrict the geometry of teeth in height-to-width ratio. In order to avoid these problems, a new forming process has been developed. Using determined material pre-distribution, it is possible to produce the teeth by the newly developed process of face gear coining with defined material flow.This paper describes the design and functionality of the new forming process. Furthermore, the proposed process is explained and compared with the conventional approach of coining using numerical simulations. In order to investigate the influence of preform parameters on the full filling of the teeth shape, a parameter study in design and geometry is conducted. Based on simulation results, the newly developed forming process is integrated in an already existing process chain. By means of this investigation, the potential of this innovative forming process will be indicated.