Computer simulation to predict stresses, working pressures and deformation modes in incremental forging of spur gear forms

Incremental upset-forging of spur gear forms around the surfaces of short length axisymmetric billets of different length to diameter ratios is simulated using a free body equilibrium approach based on the slab method of analysis. The mechanics of the process are analysed employing both the mixed cylindrical and Cartesian coordinate systems as well as an entirely cylindrical coordinate system. The theoretical results of die loads estimated from the above approaches are compared with those observed experimentally and calculated previously by the authors using the upper-bound elemental technique. Copyright (C) 1996 Elsevier Science Ltd.