Near-net shape forging of spur gear forms: An analysis and some experiments

Abstract

The paper presents the results of an experimental investigation carried out in quasi-static incremental upset-forging of spur gear forms around the periphery of initially solid cylindrical billets, the outer radius of each of which was of the same size as the radius of the dedendum circle of the spur gear to be forged. The punch or die used was of the same size and shape and had the same number of teeth at its circumference as that in the female stationary die and corresponds to the shape and size of the gear to be forged in each case. For the analysis an upper bound elemental technique previously applied to spline forging was first modified for the tapered teeth and was subsequently adopted to the analysis of forging spur gear forms having the actual profile teeth around its circumference each with the pressure angle of 14½°. The results of theoretical investigations presented here are confirmed with experiments and are compared with the existing upper bound analysis.