Journal of

Materials
Processing
Technology
ELSEVIER J. Mater. Process. Technol. 45 (1994) 25-30

P r e c i s i o n F o r g i n g S t r a i g h t and H e l i c a l S p u r G e a r s

M.H. Sadeghi a and T.A. Dean b

a Dept. of Mechanical Engineering, Tarbiat Modarres University & Press Iran Co. Tehran, Iran

b School of M a n u f a c t u r i n g and M e c h a n i c a l E n g i n e e r i n g & IRC. for Mat er i al s for High

Performance Applications, Birmingham University, U.K.

Aspects of the precision forging straight and helical spur gears including die design, preform design,
dimensional accuracy of tooth forms, forging loads and ejection problems are reviewed. The effect of
gear geometry and process variables on forging pressure and ejection load are discussed. Based upon
results of experiments performed by the authors and a literature review, proposals are made for
designing preforms for precision forging simple and compound straight and helical spur gears.
Experimentally obtained traces of forged teeth are compared with theoretical profiles of the
corresponding die and final forging.

1. INTRODUCTION
In recent years, there has been increased
Usually, gears are produced either by shaping
interest in the production of gears by precision
or bobbing. Due to the complex contours and
forging. Precision forging enables gear teeth to
high accuracy requirements of the gear teeth,
be m a n u f a c t u r e d to nett or near nett
gear m a n u f a c t u r i n g is highly specialized,
tolerances, resulting in significant savings in raw
inherently demanding of machining time and
material and production time compared with
t h e r e f o r e costly. M a t e r i a l wastage is also
c o n v e n t i o n a l cutting methods. Improved
another problem in these processes.
mechanical properties and if cold coining is
In recent years forming techniques have
used, surface finish of the finished part and
been i n t r o d u c e d as a l t e r n a t i v e p r o d u c t i o n
higher production rates are added advantages.
routes. These include fine blanking, press
Furthermore, this a p p r o a c h to g e a r
shaving, roll forming and precision forging. The
m a n u f a c t u r e is less d e p e n d e n t on the
aim of these processes is to produce gears near
availability of specialized machine tools and
to finished form.
skilled labour required to set up and operate
Fine blanking and press shaving is limited to
them compared with c o n v e n t i o n a l cutting
gears of up to about 6 mm width (although one
methods. Due to the high cost of tooling,
report [1] suggests thicker gears can be made by
precision forging of gears is unlikely to be
warm shaving). Material yield and mechanical
profitable for small volume production. High
properties are not significantly improved
volume production makes the precision forging
compared to conventional means. Roll forming
of gears, an attractive production route for
has a slow production rate [2] and often can not
automotive industries.
be justified by cost. It is also limited to ring
In c o n t r a s t to the above advantages,
gears while precision forging can be used for
precision gear forging is associated with
variety of sizes of solid or hollow gears.

0924-0136/94/$07.00 © 1994 - Elsevier Science B.V. All rights reserved.

SSD1 0924-0136(94)00155-3
26
punch
container _ _
bolster , '~ ~/ " . "", i ~" "'"
' '~ """
(a) fixed container
Figure 1. Die-set designs liar forging spur and helical gears.
problems related to die design, preform volume
and geometry, tooth dimensional accuracy, load
a n d e n e r g y p r e d i c t i o n and f i n a l l y e j e c t i o n
problems. These are reviewed in this paper.
2. DIE DESIGN
in Fig.1. two basic die-set designs for forging
s p u r or h e l i c a l gears are s h o w n . In b o t h
alternatives female forms of the gear teeth are
machined in the c o n t a i n e r bore. The anvil has
teeth m a c h i n e d r o u n d its periphery and is a
close fit in the c o n t a i n e r . The die is thus
scraped clean when the anvil moves upwards to
eject each forging.
l n d e s i g n (a) the only moving part is the
punch which enters the c o n t a i n e r to deform
t h e w o r k p i e c e . F o r f l a s h l e s s f o r g i n g the
periphery of the punch must be gear shaped as
is the anvil.
The punch in design (b) does not enter the
c o n t a i n e r b u t closes the cavity by p u s h i n g it
against light s u s p e n s i o n springs, The punch
does not need to be accurately machined to fit
the container and in general can be made more
cheaply than that in design (a). The general
mode of cavity filling in design (a) is the reverse
of that for design (b).
}:~'..i:,;i"i:?:,,7:~;71'{ punch
~r-7-n container
' d" ,' " " ,; f,. j ,e ÷,
....
i'..'"", "' . . . . . . . . ".',.,"...".'. b~)Islel
(b) movable containm
3. D E S I G N OF P R E F O R M V O L U M E AND
GEOMETRY
As in any other precision lorging process,
exact control of billel volume is a problem in
precision gear forging. This problem has been
discussed by different investigators including
Dean [31, M e y e r - N o l k e m p e r [4] and Nediani
[5]. O p t i m u m p r e f o r m g e o m e t r y is a n o t h e r
p r o b l e m to be dealt with. 111 order t o o b l a i n
defect free gears with adequately filled corners,
the correct p r e f o r m g e o m e t r y is necessary°
Furthermore, preform geometry influences the
forging load r e q u i r e m e n t s to fill a die cavily.
T h e r e is little q u a n t i t a t i v e i n t ' o r m a t i o n on
p r i n c i p l e s of p r e f o r m design for precision
forging in the literature. Here, based upon the
r e s u l t s of e x p e r i m e n t s p e r f o r m e d by the
authors [6] and literature review, the following
design p r o p o s a l s have b e e n layed down for
designing preforms for precision forging straight
or helical spur gears.
* The volume of the preform should be equal
to that of the final gear volume and should
be closely c o n t r o l l e d in o r d e r ~o avoid
underfilling or overstressing of tools.
* T h e g e o m e t r y of p r e f o r m s s h o u l d be
designed in such a w a y that an u p s e t t i n g
mode of flow predominates. This gives beUer
die filling and less load requirements [7,8].
* In elevated temperature forging, if contact

,Forged Tooth Profile
B~,eCi.'e I ~1 ~" / I B..~Cir¢'e
Forged Too-'th Proflh
(Experiment)
Figure 2. S u p e r i m p o s i t i o n of the experimentally
obtained profile of a forged tooth on
theoretical profiles of the corresponding die and
final forging, for forging at 1000°C temperature
with t h e side walls of the die occurs b e f o r e
the c o r n e r s are filled, t h e c o m b i n a t i o n of
increased frictional resistance and increased
yield strength through cooling, makes filling
of the corners extremely difficult. Therefore,
the geometry of preform should be designed
to delay side wall contact.
* F o r f o r g i n g h o l l o w g e a r s , use of h o l l o w
preforms are most advantageous. The
g e o m e t r y of t h e h o l l o w p r e f o r m s h o u l d be
designed for outward flow and minimum side
wall contact (i.e. minimum amount of sliding
across female form of gear teeth of die).
* F o r good die filling, t h e p r e f o r m g e o m e t r y
s h o u l d not p r o d u c e fin u n t i l t h e very end of
the forging operation.
* In case of u s i n g c y l i n d r i c a l p r e f o r m s for
d o u b l e spur or helical gear, for a given boss
diameter (root diameter of smaller gear), the
smaller the outside diameter of the preform,
the easier is the filling of the boss.
* In case of cylindrical preforms, the maximum
o u t s i d e d i a m e t e r of the p r e f o r m s h o u l d be
equal to root diameter of the smaller gear in
o r d e r to e l i m i n a t e free u p s e t t i n g stage and
possible folding over problems.
* if p r e f o r m g e o m e t r y is d e s i g n e d for radial
27
flow i n t o t e e t h , s t r o n g e r t e e t h will be
p r o d u c e d . T h i s type of flow, is likely to
r e d u c e t h e a m o u n t of s l i d i n g a c r o s s t h e
female form teeth surface, hence, reduces die
wear.
For forging hollow gears, ring p r e f o r m s with
maximum outer diameter and a clearance
between their inner diameter and mandrel,
will r e s u l t in t h e m o s t f a v o u r a b l e s u r f a c e
strains at the tooth tips. This will help reduce
t h e l i k e l i h o o d of s u r f a c e c r a c k i n g at t h e
tooth tips during deformation 19].
4. DIMENSIONAL ACCURACY
In precision gear forging the ultimate aim is
to p r o d u c e gears with i n t e g r a l t e e t h w i t h o u t
t h e n e e d for a n y p o s t - f o r g i n g m a c h i n i n g
operations. This requires design and
manufacture of dies with consistent accuracy. In
p r e c i s i o n gear forging, t h e r e m u s t be s m a l l
differences between the dimensions of the gear
shaped die cavity and the forged gear. This is to
compensate for the following changes:
(i) U n d e r t h e f o r g i n g l o a d s , die c a v i t i e s
e x p a n d elastically, t h u s its initial d i m e n s i o n s
must be made smaller.
(ii) If t h e w o r k p i e c e is at a n e l e v a t e d
t e m p e r a t u r e , dies are p r e h e a t e d and t h e r e f o r e
expand and the cavity should be made smaller.
(iii) Post forging contraction of the
c o m p o n e n t occurs at e l e v a t e d t e m p e r a t u r e s
therefore, the die cavity must be made larger.
(iv) In p r e c i s i o n g e a r f o r g i n g , dies a r e
normally made by electro- discharge machining.
Due to the s p a r k gap allowance, t h e e l e c t r o d e
should be made smaller.
H e n c e , to o b t a i n a c c u r a t e forged gears, the
e x t e n t of e a c h of t h e a b o v e f a c t o r s has to be
calculated and allowed for. Using the values of
d i m e n s i o n a l c h a n g e derived previously for solid
28

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.......
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Figure 3. variation of relative forging pressure Figure 4. Variation of ejection load with numbcl
with deformation for various number of teeth in of teeth and gear module ti)r lZ)rging spur gears
forging solid straight spur gears
r e m a r k a b l y higher after the f o r m e d teeth
cylinders [10], the above factors affecting final c o n t a c t e d the die wall, i.e. d u r i n g c o r n e r
forging dimension can be used to determine the filling stage.
relation between the radius of die and of forging. * For a given gear module and width, Iorging
Assuming every point on a radius of forging pressure increases by increase in number of
moves only along that radius, it has been found teeth (see Fig.3).
that profile of a forged tooth in an involute die * F o r g i n g p r e s s u r e v a r i e s very l i t t l e with
t o o t h cavity r e m a i n s i n v o l u t e [ l l ] . Fig.2 increase in gear modnle during the first stage
compares the experimentally obtained traces of of d e f o r m a t i o n and before the formed lecth
forged teeth at 1000 C with theoretical profiles contact the die wall. D u r i n g c o r n e r filling,
of the c o r r e s p o n d i n g die and final forging. It the pressure increases considerably as the
has been found that the post-forged profile of a gear module increases.
t o o t h forged in an i n v o l u t e die t o o t h cavity * Forging pressure increases very slight ly wit h
remains involute [111. increase in helix angle over the entire range
of deformation.
* For a given gear size, the thinner the gear,
5. LOAD AND ENERGY PREDICTION the higher the forging load requirements.
~' Forging pressure increases with increase in
T h e r e are few d e v e l o p e d load prediction b o r e d i a m e t e r and this i n c r e a s e in m o r e
m e t h o d s for p r e c i s i o n gear forging. A considerable during corner filling stage.
theoretical model based on the energy method,
for predicting forging load and bulged surface
p r o f i l e of the t e e t h when forging s t r a i g h t or 6. EJECTION PROBLEMS
helical spur gears has b e e n p r e s e n t e d by the
authors peviously [6,12]. It has been found that; In c o n v e n t i o n a l d r o p f o r g i n g in o r d e r to
* The forging pressure increases considerably enable the workpiece to be removed easily from
and p r o g r e s s i v e l y with d e f o r m a t i o n as the the die, a draft angle is used. In general, as the
f r i c t i o n f a c t o r increases. The i n c r e a s e is draft angle decreases, more force is required to

(a) (b)
F i g u r e 5. T o o l i n g M i s m a t c h a) P r e c i s i o n
i m p r e s s i o n in o n e die half (No mismatch) b)
P r e c i s i o n i m p r e s s i o n in b o t h die h a l v e s
(Mismatch arises)
e j e c t t h e f o r g i n g f r o m t h e die cavity. In
precision forging although some degree of draft
angle can be used in preforming to ease ejection,
in the final s t a g e usually no draft can be
allowed on the component. This makes forged
straight and helical spur gears more difficult to
eject and distortion of final product may occur.
E j e c t i o n of the helical gears b e c o m e s m o r e
difficult than s p u r gears due to the helix
angle. I n c r e a s e in helix a n g l e causes m o r e
frictional resistance during ejection, therefore,
making the release of the c o m p o n e n t from the
die even more difficult.
A t h e o r e t i c a l analysis for predicting loads
required to eject straight and helical spur gears
has been developed by the authors [13]. It has
been found that;
* For a constant gear height, the ejection load
increases with increase in friction factor.
* The higher the forging load, the m o r e the
gear cavity filling and t h e r e f o r e , the m o r e
the interface contact area, resulting in higher
ejection load requirements.
* T h e h i g h e r the f o r g i n g t e m p e r a t u r e , the
lower the ejection load.
* For a spur gear with given module, pressure
angle and width, ejection load increases by
29
increase in number of teeth. The increase in
e j e c t i o n load with i n c r e a s e in n u m b e r of
t e e t h , is g r e a t e r for g e a r s with h i g h e r
modules (see Fig.4).
* For a spur gear with given number of teeth,
p r e s s u r e a n g l e and width, e j e c t i o n load
increases by increase in gear module. The
increase in e j e c t i o n load with increase in
gear module, is greater for gears with greater
numbers of teeth.
* For a spur gear with given module, pressure
angle and width, ejection load increases with
i n c r e a s e in helix angle. T h e g r e a t e r the
n u m b e r of teeth, the g r e a t e r the effect of
helix angle on ejection load.
* For a spur gear with given pressure angle and
width, n o n - d i m e n s i o n a l e j e c t i o n pressure,
decreases with increase in either number of
teeth or gear module. The lower the number
of teeth, the greater the effect of gear module
on e j e c t i o n pressure. Also, the lower the
gear module, the greater the effect of number
of teeth on ejection pressure.
* For a spur gear with given module, number
of t e e t h , p r e s s u r e a n g l e and w i d t h , the
non-dimensional ejection pressure increases,
with f r i c t i o n factor and helix angle. This
i n c r e a s e is g r e a t e r at h i g h e r f r i c t i o n a l
conditions and higher helix angles.
7. OTHER PROBLEMS
P r e c i s i o n f o r g i n g of gears w o u l d be
economical, if the dies can be designed and
produced with consistent accuracy at reasonable
cost. Die design can influence the deformation
pattern and t h e r e f o r e r e q u i r e d forging load.
The dimensional accuracy of final forged gears
is also affected by die design.
S u r f a c e d e g r a d a t i o n and wear of the die
surface and degradation of the workpiece due to
oxidation can occur in elevated t e m p e r a t u r e
30
forgings. Wear of the critical surfaces of the die
is also a n o t h e r problem. These two factors
together with the accuracy required, determine
the die impression life and therefore the overall
cost of the process.
In elevated temperature forgings formation
of an oxide film (scale) on the surface of the
forging can lead to surface defects. This
problem can be c o n t r o l l e d by the use of
p r o t e c t i v e a t m o s p h e r e s or low preheat
temperatures.
When the impression lies in one die-half no
die mismatch occurs, but when it is formed in
both die-halves (Fig.5), tooling mismatch can
arise (i.e. concentric and rotational mismatch).
By use of accurate guides concentric mismatch
can be reduced and rotational mismatch can be
kept low using keys, but depending upon the
accuracy required, these measures can be
difficult and costly.
8. CONCLUSION
Various aspects of the precision forging
straight and helical spur gears including die
design, preform design, dimensional accuracy of
tooth forms, forging loads and ejection problems
have been reviewed. Based upon results of
experiments performed by the authors [6] and a
literature review, some design proposals have
been layed down for designing a preform for
precision forging straight and helical spur gears
and compound gears. Experimentally obtained
traces of forged teeth are compared with
theoretical profiles of the corresponding die and
final forging and it has been found that profile
of a forged tooth in an involute die tooth cavity
remains involute. Effects of gear geometry and
process variables on forging pressure and
ejection load are discussed.
REFERENCES
1. M.Murakawa, et al. Production of Thick Spur
and Helical Gears by Warm Shaving Proc. of
14th NAMRC, (1986), pp. 445-451.
2. J.B. Hawkyard, et al. Cold Rolling of Ring
Gears Proc. of the 15th I n t e r n a t i o n a l
M.T.D.R. C o n f e r e n c e , U n i v e r s i t y of
Birmingham, (1974) pp.507-513.
3. T.A. Dean The Feasibility of Flashless
Forging Metallurgia and Metal Forming,
Vol.44, NOS. 11 and 12, NOV. & DEC.
1977, PP. 488-498 and 542-544.
4. H. Meyer-Nolkemper Werzeuge zum form
pressure ohme Grat (Tools for flashless
forging) Industrie Anzeiger, If)l, JG, N r. 73,
12/9/1979.
5. G . N e d i a n b A n I n t r o d u c t i o n to llashless
forging of long shapes Ph.D. Thesis, 1982,
Birmingham University.
6. M . H . S a d e g h i ~ P r e c i s i o n Forging
Axisymmetric Shapes, Straight and Helical
Spur Gears Ph.D. Thesis, 1989, Birmingham
University.
7. S.K. Biswas and W.A. K n i g h b C o m p u t e r
Aided Design of Axisymmetric Hot Forging
Dies Proc.15th Int. M.T.D.R. Conf., 1974,
8. T. Altan, S. Oh and H.L. Gegel, Metal
Forming : Fundamentals and Applications,
A.S.M. Series in Metal Processing, Ohio,
1983.
9. M. Robinson~A Workability Analysis of the
Cold Forging of Gear with Integral Teeth, J.
of Mech. Working Tech. 1 (1977/78).
10. M.H. Sadeghi and T.A. Dean "Analysis of
Dimmensional Accuracy of Precision Forged
Axisymmetric Components" 1~ Mech. E.
vol.205 , London, 1991
II.M.H. Sadeghi and T.A. Dean "Analysis of
Tooth Profile Accuracy in Precision Forged
Spur Gears with Involute Teeth" Proc. Conf.
of SME/NAMRC, Vol.21 ,1993
12. M.H. Sadeghi and T.A. Dean "Mathematical
Modelling & Experimental Validation of
the Precision Forged Straight & Helical Spur
G e a r F o r m s " A S M E , 1993 ( s e n t for
publication)
13. M.H. Sadeghi and T.A. Dean "The Ejection
of Precision Forged Straight & Helical Spur
Gear Forms" J. of Materials Processing
Technology, vol.31 , 1992