Spur gear forging tool manufacturing method considering elastic deformation due to shrink fitting

This research introduces an advanced manufacturing method for gear part tools. In the conventional method, wire cutting and lapping of the corner region were performed after shrink fitting to ensure the accuracy of the gear profile. But lapping is difficult when the corner region is located inside of the die. The new tool manufacturing method suggests that wire cutting and lapping are performed after the 1st shrink fitting to facilitate lapping operation and to increase the accuracy of the corner radius. Finite element analysis and forging test are performed. Comparison between analysis and measurement of forged part ensures the validity of suggested tool manufacturing methods.