Abstract
A theoretical model for predicting the forces required to eject forged straight or helical spur gears from a die is presented. The effects of forging load, friction factor, die wall/workpiece contact area on the ejection load for straight and helical spur gears forged at room temperature has been investigated. The effect of number of teeth, gear module, helix angle and gear height on the ejection force are determined. Experimental results for room temperature are compared with the theoretical predictions. It has been found that the ejection force increases with increase in the forging load, friction factor and contact height, whilst increase in the gear module, number of teeth and helix angle all lead to an increase in the ejection force.
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