Recent developments in the extrusion of helical gears

With an improved die, a method for manufacturing gears by means of tube extrusion has been developed to a stage where, without noticeable wear of the die, 40,000 workpieces can be manufactured. The paper presents a numerical analysis of the stresses and deflection of the die, offering also a comparison between the modified and the conventional symmetric orifice. Based on the results obtained and using recent work on crack prediction for extrusion dies, the area most prone to rupture is determined. Moreover, a concept for the precorrection of the die is offered to improve the tooth quality of the gears.