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TECHNICAL PAPERS

Gear Forging: Mathematical Modeling and Experimental Validation

[+] Author and Article Information
M. H. Sadeghi

Mechanical Engineering Department, Tarbiat Modarres University, Tehran, Irane-mail: sadeghim@modares.ac.ir

J. Manuf. Sci. Eng 125(4), 753-762 (Nov 11, 2003) (10 pages) doi:10.1115/1.1616952 History: Received December 01, 2001; Revised March 01, 2003; Online November 11, 2003
Copyright © 2003 by ASME
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References

Figures

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A deformation unit and its three regions
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A deformation unit showing bulged free surface of tooth form
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Simplified flowchart of the computer program for modeling precision gear forging process
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A deformation unit divided into 2n slices for analysis
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Flow stress-strain curve for commercially pure lead 11
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General assembly of the die set for spur gear forging tests
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Flow stress versus forging temperature for medium carbon steel obtained from ring compression tests at strain value of 0.75
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Friction factor versus forging temperature obtained from ring compression tests
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Photographs showing deformation profile of a forged spur gear at three different stages, a) partially forged (showing bulged free surfaces of the teeth), b) formed teeth contacted the outer die wall, c) complete teeth are formed
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Variation of relative forging pressure with deformation for various friction factors in forging solid spur gears
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Relation between relative forging pressure and height—A comparison of experimental and theoretical results
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Variation of relative forging pressure with deformation for various numbers of teeth in forging solid spur gears
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Variation of relative forging pressure with deformation for various values of gear module in forging solid spur gears
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Variation of relative forging pressure with deformation for various values of helix angle in forging hollow helical gears
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Variation of relative forging pressure with deformation for various values of gear height in forging hollow helical gears
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Variation of relative forging pressure with deformation for various values of bore diameter in forging hollow helical gears
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Experimental and theoretical bulge surface profile of teeth in forging solid spur gears

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