Precision Cold Forging of a P/M Preform to Produce a High Density Spur Gear

This paper describes the manufacture of a seventeen tooth spur gear by Precision Cold Forging (PCF) of a P/M preform to over 98% of theoretical density. This gear is currently being validated to replace a cut gear used in a 24hp garden tractor transmission. The method described is a bulk deformation process requiring close control of densification and deformation of the sintered preform within the fracture limit of the material.