CLOSED-DIE FORGING OF GEAR-LIKE ELEMENTS

Closed die forging of spur gears is investigated using the slab method and the upper bound technique. The tooth regions are approximated by prismatic rectangular sections. The velocity field comprising three un it deformation regions is used. A constant frictional stress between w orkpiece and forging die is assumed. The average punch pressure normal ized by the flow stress of the gear material is determined theoretical ly and compared with experimental results. The experimental work is ca rried out on a commercial pure aluminum (Al 1100) at room temperature. The forging process is carried out using one die geometry without usi ng any additional blocker (preform) dies. The theoretical predictions of forging pressures using slab and upper bound methods agree fairly w ell with the experimental results.