Distortion minimization of disks for gear manufacture

► Case hardened disks show a dishing behavior which seems to depend on the local shape of the banded structure. ► It is assumed that an interaction between casting, hot forming and cutting exists and that it is responsible for dishing. ► Dishing can be minimized by an adapted material removal partition. ► A combination of a symmetrical mass flow during forming and a symmetrical material removal during machining avoids dishing. ► When using spray-formed material dishing is negligible.