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Design and implementation of hot precision forging die for a spur gear

Maşat, Mehmet
There is a strong need in forging industry to reduce waste of material, improve quality, and reduce cost of forgings. About 30% of the material is wasted during conventional closed-die forging. Therefore, in order to reduce the cost of forged products and to obtain near-net or net shape parts, new forging methods should be applied. Precision forging concept is a cost-effective way to produce net-shape or near-net shape components. In recent years, there has been an increased interest in the production of gears by the net-shape forging technique. This has specific advantages over the traditional manufacturing processes of cutting gears such as hobbing, turning, and grinding including savings on cost and raw material, increased productivity, and gears with higher dynamic properties than conventionally cut ones. In this study, precision forging of a particular spur gear has been investigated. The precision forging die set has been conceptually designed and modeled in a computer aided design environment. The forging process of particular spur gear has been simulated by using a commercially available finite volume program. After the successful simulation results, the prototype die set and the tube-shaped billets were manufactured. The real-life experiments have been realized by using 1000 tons mechanical forging press available in METUBILTIR Research and Application Center Forging Laboratory. The results have been compared with the computer simulations. After the real-life experiments, it has been observed that the conceptual die design is appropriate and near-net shape spur gears are successfully obtained by the proposed precision forging die set.