Abstract
Dynamically highly stressed mechanical-transmission parts such as gears and drive flanges can be economically produced by forging. Hollow parts, such as gears, are conventionally forged with a web at the centre which is punched out later and the bore then machined to the required dimension. These punching and machining operations cause material waste and increased cost. In order to forge hollow parts with an accurate bore and to eliminate problems caused by the web, the authors have explored a method for precision forging hollow billets. Because the highly-stressed centre-web region is eleminated when hallow billets are used, a more homogeneous stress distribution arises in the die, allowing more complex shapes to be forged. In this paper, advantages of using hollow billets for precision forging hollow components with accurate bores are discussed. General problems and requirements of dies for flashless forging are outlined and alternative designs are presented. Various hollow shapes which have been precision forged from hollow billets, in dies of novel design, are described.
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