Design and manufacturing of asymmetric spur gear forging die

Asymmetric gears have some advantageous in one directional motion. But, due to the profile geometry, the production with the conventional cutting method limits the design of the profile. Recent studies in this area have shown that asymmetric profiles designed independently from the cutting tool are more efficient. Therefore, in this study, a precision forging die of an asymmetric spur gear was designed and the design criteria were presented. Because the die is exposed to high loads and tensions during forging in a short period of time, a single ring shrink fit assembly was proposed. A design procedure for determination for the dimensions of the die components and the amount of interference was developed. The tooth profile deviations of the die due to shrink fit and the forging load of the die were also investigated. Software was developed to generate corrected tooth profile due to the above-mentioned deviations. The results predicted by the software were validated by finite element analyses. A gear die measurement system was developed based on image processing and software was integrated to automatically measure the dimensions of the spur gears. An asymmetric spur gear forging die was designed and manufactured using the presented criteria. The dimensions of the die were measured by the developed image processing system and CMM. The CMM measurements and the image processing algorithm results are in good agreement. The results show that the developed inspection system can be used for asymmetric gear measurements with the advantages of less time requirements.