Differences between traditional cold forging and cold orbital forging of a spur bevel gear

Cold orbital forging, as an advanced incremental forming process, has been widely researched and used to fabricate the spur bevel gear. However, the mechanism of cold orbital forging is quite different from that of traditional cold forging, which leads to the different forming laws and different properties of forged gear. In this paper, cold orbital forging and traditional cold forging of a spur bevel gear are simulated under the same conditions in the Deform-3D software platform. The filling process, geometric characteristics of forged gear, effective stress distribution, effective strain distribution, gear tooth accuracy are comprehensively clarified and compared. The results show that, comparing with traditional cold forging of a spur bevel gear, cold orbital forging can increase the degree and homogeneity of plastic deformation and improve the gear tooth accuracy.