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The research subjects of current investigations at the Institute for Metal Forming Technology (IFU) Stuttgart include the manufacture of face gearings. Usually, gearings are produced by means of a coining process, which causes high process forces that considerably restrict the geometry of the teeth in terms of the height-to-width ratio. In order to avoid these problems, a new forming process has been developed. This technology offers significant advantages, such as the reduction of process forces and the ability to manufacture the required tall and acuminate tooth elements through a cold-forming process. This paper describes the design and functionality of the novel pin-to-gear forming process. In this paper, the operating principle of the method is presented first of all. The new pin-to-gear process is then compared to conventional coining and the free-divided-flow (FDF) process developed at IFU Stuttgart in 2018. This examination takes the form of a numerical simulation using DEFORM-2D software. To investigate the influence of preform parameters on the form filling of the tooth cavities, parameter studies in design and geometry are conducted. Process limits regarding geometric constraints are presented alongside possibilities for increasing process reliability. Through this investigation, the potential and opportunities of the innovative pin-to-gear forming process will be illustrated.

Numerical Investigation of a New Production Method for Face Gearings Incorporating Material Predistribution – Pin-to-Gear Method