New forging tool manufacturing method for spur gear part

Abstract

This study introduces an advanced tool manufacturing method regarding manufacturing procedures. With conventional methods, wire-cutting and lapping operations of the corner and render regions are performed after shrink fitting to ensure the accuracy of the gear profile. However, lapping is very difficult when the corner and render are located deep inside the die. The new tool manufacturing method suggests that wire cutting and lapping are performed after the first shrink fitting to facilitate the lapping operation and increase the accuracy of the corner radius. After lapping is completed, the second die ring is shrink fitted. The amount of elastic deformation by the second shrink fitting and cold forging can be calculated through finite element analysis. Wire-cutting specifications can be offset as predicted in terms of the amount of elastic deformation. Gear dimension comparison of the analysis and forged parts ensures the validity of the new tool manufacturing method.