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Forging Forming for Gear Machining
2025-08-20
Typically, larger-specification bevel gears are formed using specialized, high-tonnage hydraulic closed-die forging presses, while smaller-specification bevel gears are more commonly produced on standard cold-forging presses equipped with dedicated closed-die tooling. The latter method offers the advantages of high production efficiency and lower costs. However, the size of the forged parts is limited by the clamping force of the die set, making it unsuitable for shaping large-sized bevel gears.
Considering the cost-effectiveness of gear mold manufacturing—particularly for cemented carbide gear dies—the primary molding process currently used in the precision gear forging industry remains electrical discharge machining (EDM). However, the gear-shaped electrode generating process has increasingly been replaced by high-speed CNC milling. For warm- and hot-forging molds requiring quench-hardness levels around Rockwell 50, high-speed milling has already surpassed EDM in both machining speed and precision, while also demonstrating clear advantages in terms of mold life. As long as the cost of tooling can be effectively managed, high-speed milling could completely replace EDM for warm- and hot-forging gear molds.
Another outstanding advantage of the forward extrusion forming process is that the die tooth profile is precisely manufactured using CNC wire-cutting. When producing gears with a small number of teeth, this method allows for the ideal tooth shape to be achieved simply by programming—eliminating concerns about undercutting. Moreover, when machining special or modified gear profiles, CNC wire-cutting proves far more convenient, faster, and accurate compared to traditional gear generating or contouring methods.
Keyway cold forging is a special case of positive gear extrusion forming. The forming of involute keyways is equivalent to extruding a longer spur gear, while the extrusion process for rectangular keyways closely resembles that of involute keyways. Alternatively, small-module spur gears can be produced by dividing an involute keyway shaft into segments.
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