Abstract
Accurate filling of various teeth forms on components is one of the challenging aspects in cold forging die design. The complete filling of the finest detail is either not possible or could be achieved only at the cost of excessive die stresses and process loads. Current research addresses these drawbacks with two different alterations in material flow strategies applied to lateral and face gearings. The first material flow strategy appears to be a modification of the conventional Samanta process for the cold forging of gears. The second strategy is an efficient alternative for the direct coining of gearings on flat faces. These proposals provide improved material filling and reduced tool loads at the same time.
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