Upper bound Analysis of injection forging gear like components with radial toothprofile and tapered tooth profile, using the computer program MAPLE

time manufacturing of gears and gear-like components by metal forming operations has been under intensive growth; one of the best methods for forming gear-like component is injection forging because of its economical production. High rate of production, high dimensional accuracy, better surface quality, enhancing strength of material due to work hardening, raw material saving and reducing shear process are some of ejection forging advantages than shearing. In this manner forming load calculation are very important. One of the analytical methods to calculate the forming load is upper bound. In this cold injection forging of gear-like components has been investigated theoretically. Two different teeth-geometries with radial and tapered profile have been analyzed. An upper bound approach has been used to develop mathematical model to predict the main process parameters. For analysis, a gear-like component with N teeth number was divided into 2N numbers of similar segments. Then, material under deformation in a segment was further sub-divided into some deformation units. For investigate this deformation units we simulate process with Super forge. Simulation results for radial tooth profile show that material flows in straight way until material get the end of tooth then material fill the tooth. For tapered tooth profile a new kinematically admissible velocity field with optimization parameter is proposed. From the proposed velocity field the upper bound solution on extrusion load were determined with respect to chosen process Parameters. The theoretical results were compared with theoretical and experimental results from a reference to illustrate the admissible velocity fields. Finally effects of different parameters on the extrusion load were studied.