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.

Issue Section:
Research Papers
Topics:
Forging, Gears, Slabs, Stress, Aluminum, Deformation, Flow (Dynamics), Geometry, Preforms, Pressure, Spur gears, Temperature
1.
Hwang
S. M.
, and
Kobayashi
S.
, “
Perform Design in Disk Forging
,”
Int. J. Mech. Des. Res.
, Vol.
26
, No.
3
, pp.
231
–
243
,
1986
.
2.
Yang
D. Y.
, and
Kim
J. H.
, “
An Analysis for Three-Dimensional Upset Forging of Elliptical Disks
,”
Int. J. Mech. Tool Des. Res.
, Vol.
26
, No., pp.
147
–
156
,
1986
.
3.
Ibhandode
A. O. A.
, and
Dean
T. A.
, “
Corner Filling Characteristics in Precision Forging
,”
Int. J. Mech. Tools Manufact.
, Vol.
28
, No.
2
, pp.
103
–
122
,
1988
.
4.
Kim
J. H.
,
Yang
D. Y.
, and
Kim
M. U.
, “
Analysis of Three-dimensional Upset Forging of Arbitrarily-shaped Prismatic Blocks
,”
Int. J. Mech. Tools Manufact.
, Vol.
27
, No.
3
, pp.
311
–
323
,
1987
.
5.
Sun
J. X.
, “
Analysis of Special Forging Processes for Heavy Ingots by Finite Element Method
,”
Int. J. Mech. Tolls Manufact.
, Vol.
28
, No.
2
, pp.
113
–
179
,
1988
.
6.
Gupta
N. K.
, and
Shah
C. B.
, “
Barreling of Short Cylinder in Compression
,”
Int. of Mech. Tool Des. Res.
, Vol.
20
, No.
2
, pp.
137
–
146
,
1986
.
7.
Abdul
N. A.
, and
Dean
T. A.
, “
An Analysis of the Forging of Spur Gear Forms
,”
Int. J. Mech. Tool Des. Res.
, Vol.
26
, No.
2
, pp.
113
–
123
,
1986
.
8.
O. P., Grover, and L., Juneja, “Analysis of Closed-die Forging of Gear-like Element,” Advanced Technology of Plasticity, Vol. II, The Japan Society for Technology of Plasticity, pp. 888–893, 1984.
9.
Metal Handbook, American Society for Metals—Vol. 14, 9th Ed., Forming and Forging, 1989.
10.
Metals Handbook—Desk Edition, American Society for Metals, 1989.
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