Precision Forging of Spiral Bevel Gears for Army Helicopters

摘要

The objective of the project was to develop an alternate manufacturing method for spiral bevel gears used in Army helicopters. The report covers the technical description of a program to develop high velocity forging techniques to produce spiral bevel gears to pre-grind tolerances. Initial objectives were to obtain as-forged gears with .005 inches excess material on the side of each tooth for finish grinding after the heat treating. The report includes a discussion of die design parameters, the manufacturing techniques for dies, forging parameters, dimensional checks of the forged gears, machining techniques for determining as-forged geometry and macroscopic and microscopic metallurgical data showing grain flow and micro-structure. Also included is a discussion of difficulties experienced and recommendations for future investigations. (A THOR)