Near-net shape forging of a crown gear: some experimental results and an analysis

This paper presents a few salient results of an experimental investigation made into the quasi-static progressive incremental closed-die forging of cr own gear forms starting initially from both solid and hollow circular cylin drical specimens made of tellurium lead as the model material. The detailed observations made on the die loads and the deformation modes, etc, at vari ous incremental stages are given and these are compared with those based on an upper bound simulation of forging of the crown gear with rectangular an d trapezoidal shaped teeth. The tooth profile patterns are also compared wi th the resultant CAD outputs based on the upper bound analysis. Reasonably good correlations between the experimental observations of die loads and to oth profile patterns with those estimated from theoretical simulations were obtained and these and other results given are commented upon. (C) 2001 El sevier Science Ltd, All rights reserved.