ANALYSIS AND DESIGN OF PINION WITH INNER HELICAL GEAR BY FEM

Cold forging of pinion gear with shape of outer spur gear and inner helical gear have been investigated in this study. A numerical analysis for preform design substituting cutting process in gear forging was developed by means of upsetting process. By using the finite element program DEFORM-3D, the analysis is carried out. Using this simulation, the preform of pinion and helical gear forging process were designed. The suggested process is verified by experiment. Compared to the traditional CNC processing, the upsetting process can form a preform without cutting, which leads to shorter forming time and reduce material usage.