Forming of Spur Gear by Combination of Divided Flow Forging and Slide Motion by Using Liquid Lubricant

To reduce the processing load and improve the filling ratio of the tooth part of spur gear, combining divided flow forging and pulse slide motion using liquid lubricant was studied. The test materials were A1070 and A5056 aluminum alloy. The diameter of relief area (relief axis method) was 6 mm and the effect of relief axis height: δ and a viscosity of lubricant were investigated. The die pressure in A1070 aluminum divided flow forging with viscosity 56 cSt decreased from 850 MPa to 795 MPa for closed forging and be reduced to 750 MPa by applying pulse slide motion. However, in A5056, the load reduction due to the pulse slide motion was small, but the filling ratio increased with the number of vibrations. Controlled divided flow forging of A5056 that with back pressure resulted in lower load and higher filling ratio than conventional divided flow forging during processing at relief axis height δ = 1.5 mm and 2 mm.