Numerical Investigation of the Influence of Friction, Module and Number of Teeth in Forging Process of a Spur Gear

Abstract

Among all manufacturing processes, forging has a special place because in this technology, parts with desired mechanical properties and minimum waste of material can be produced. Gear is one of the components of machinery which should have special features such as high strength-to-weight ratio, fatigue and surface abrasion resistance, etc. So, comparing with other methods, gear forging provides above requirements. Moreover, precision forging of gears is one of the appropriate methods for producing this piece because it saves material consumption and reduces machining costs. Extensive studies are carried out on this production method but there are also many aspects to be investigated. Since, without having knowledge of the influence of parameters such as friction conditions, material properties, and geometry of work piece on the mechanics of the process, optimal design of the form, selection of appropriate equipments, and prediction and prevention of defects that may occur is not possible, modelling the process for computer simulation has been given much attention in modern technology of metals forming. The purpose of this study is to examine factors such as number of teeth, modulus and coefficient of friction on load, and the force required for the process which has been studied using finite element method.