Adapted tool design for the cold forging of gears from non-ferrous and light metals

Abstract Due to growing competitive pressure within the manufacturing sector, there have been increasing attempts establish resource saving production methods in gear recent years. Cold forging offers potential—in addition a high material and energy efficiency—to produce gears with an excellent surface quality, increased hardness as well load adapted fiber orientation. With regard wide range of applications is broad demand for materials, ranging from high-strength steels non-ferrous light metals. The flow behavior has significant influence on cold process. Therefore, no consistent process result achieved when forming different materials. Challenges exist due deficient die filling poor resulting geometrical accuracy. In this contribution, material-specific challenges during full forward extrusion metals identified suitable tool-sided measures were derived. A validated numerical model was used determine underlying mechanisms action verify derived measures. reduced yield stress leads inflow formation, insufficient filling, low achievable strain hardening, gearing increase accuracy mechanical properties. That provides basis ready-to-use various metal