Cold forging of gears: experimental and theoretical investigation

This paper draws from fundamental research on precision forging for the dev elopment of a flexible tool system for producing gear parts. The overall in vestigation makes use of conventional spur gears. Fundamental research is u ndertaken by using virtual prototyping modeling techniques based on the fin ite element method. The utilization of such techniques provides a better in sight into the deformation mechanics during the forging process, by giving an accurate description of the material flow, filling conditions and corres ponding geometrical profiles. The finite element method also enables the pr ediction of stresses and forces exerted on tools as well as the distributio n of the major field variables in the forged parts. The application of tool design expertise in conjunction with the virtual prototyping modeling tech niques made possible the development of a tool system for performing the ex periments. The experimental work is mainly utilized for supporting and vali dating the theoretical investigation but a later stage can be further devel oped in order to put the proposed forging concept on an industrial basis. ( C) 2001 Elsevier Science B.V. All rights reserved.