Closed-Die Forging of Gear-Like Elements

Abstract

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 unit deformation regions is used. A constant frictional stress between workpiece and forging die is assumed. The average punch pressure normalized by the flow stress of the gear material is determined theoretically and compared with experimental results. The experimental work is carried out on a commercial pure aluminum (Al 1100) at room temperature. The forging process is carried out using one die geometry without using any additional blocker (preform) dies. The theoretical predictions of forging pressures using slab and upper bound methods agree fairly well with the experimental results.