Computer-Aided Design and Manufacture (CAD/CAM) Techniques for Optimum Preform and Finish Forging of Spiral Bevel Gears (Phase III)

In Phase III of the program, spiral bevel gear forging dies were designed and manufactured using the CAD/CAM techniques, developed in Phase I of the study. The gear selected for the project was a 16-1/2 inch spiral bevel gear used in the M915A16x4 tractor manufactured by AM General. Five different preform designs were tried using lead as the model material . These tests were conducted at Battelle's Columbus Laboratories using a 700 ton hydraulic press. A special induction heating system was designed and fabricated for heating the preforms. The tool design was changed to have the teeth on the upper die to ensure proper flow and filling. Machine settings for the electrode were calculated using the computer program SPBEVL and graphite electrodes were machined on a Gleason No. 28 generator.
Prepared in collaboration with Eaton Corp., Willoughby, OH.