Geometric Modeling, Upper Bound Analysis and Finite Volume Metal Simulation of Spur Gear Precision Forging

Parametric geometric modeling of spur gears, precision forging die set modeling and upper bound analysis were studied in this paper. Module, teeth number, pressure angle, gear width and bore radius of the spur gear were input to a computer program, written with Visual Basic in SolidWorks, and then solid model of that was constructed in SolidWorks. Then billet and precision forging die set were designed and modeled. For upper bound analyze, half pitch of a tooth with involute curve has been divided into six deformation zones. A new kinematically admissible velocity field that includes bulging of the tooth has been proposed. Forging load obtained using the upper bound were compared with theoretical and experimental results carried out in literature and also using SuperForge of FVM simulation package.