Powder Metallurgy (P/M) represents an energy and material saving technology suitable for a cost effective mass production of complex shape components. On the other hand P/M parts do not reach the mechanical strength offered by micro-alloyed steel components. Surface densification of as-sintered parts is a promising process technology in order to reduce this gap. This paper describes the development of a rolling process capable of densifying the tooth surface of high loaded P/M gears, with particular attention to the simulation methodology of elasto-plastic deformation behaviour. Satisfactory results have been reached, allowing a new interest of automotive designers towards P/M technology.
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