An Investigation into Forming Externally Toothed Parts using Novel Tool based on Rotary Forging Technique

Abstract

Toothed parts such as the gears, splines are typically produced by machining or casting processes. In this paper, a new method of toothed parts forming using rotary forging process with novel tool was proposed. The idea deduced from Archimedes’s principal was adopted to design the novel forging tool.  The developed tool serves as rotary forging tool and back work extrusion ram during the forming process. An experimental work was conducted to form the toothed parts and to validate the design of the developed tool. A lead metal is selected as a bulk material, whereas its behavior through forming process is similar to the hot steel.  A rotating speed (rpm), an axial feed rate (mm/rev), and tool inclination angle (ϴ) in degree are considered as working conditions. Several toothed specimens were produced at various working conditions. An experimental analysis was conducted to investigate the impact of the working conditions. The results reveal that these working conditions have a clear influence on the forging loads and characteristics of the formed part.