Finite Element Analysis of Gear Like Form by Using Lateral and Forward Extrusion

The aim of this research is the reduction in deformation load, improvement of the mechanical properties of the product by means of an optimum forming process and die profile. Forward extrusion and lateral extrusion were chosen as two different forming methods to manufacture a spur gear form.Four different die geometries were chosen for the forward extrusion; including straight tapered transition profile and cosine transition profile with having two different die lengths. Al 1070 was used as workpiece material in the experimental study. Experiments using five sets of dies with spur gear form were performed, and the measured forming load results were compared with the predictions of the finite element method for the same deformation situations by using DEFORM-3D. The state of stress and strain was also determined for two forming methods by means of DEFORM-3D. Finally, a series of fatigue tests were carried out for four teeth gear forms produced by both processes to evaluate influence of the forming processes.