The applicability of process design system for forward extrusion of spur gears

In this study, the applicability of the automated process design system developed for cold forward extrusion of solid or hollow spur gears was confirmed through experiments. Extrusion die set was designed by employing the developed system. An elastic analysis of dies considering a shrink fit was carried out to determine level of hoop and effective stresses depending on its ratios. Depending on material types and lubricants, hollow and solid gears were extruded in the present investigation. From experiments, it was found out that filling status of the hollow gear was improved in comparison with that of the solid gear irrespective of forming conditions and the predicted forming load obtained from the developed design system matched well with the experimental load requirements. From the current study, it was expected that the developed system can efficiently be used for the process and die design of gear extrusion at room temperature.