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The FE simulations and experiments of cold orbital forging of gear rack are conducted.
This paper proposes an innovative cold orbital forging method for manufacturing gear rack, in which the complicated teeth of gear rack are forged by the highly dynamic rocking tool under straight line path.
At present, gear rack is manufactured mainly by cutting method while its precision plastic forming method has not been reported.
The results demonstrate that the proposed cold orbital forging method for manufacturing gear rack in this paper is effective and cold orbital forging shows great potential in manufacturing gear rack.
Based on this universal method, the rocking tool in cold orbital forging of gear rack is accurately designed.
Secondly, the mathematical model and method for interference examinations between the rocking tool and gear rack are developed and the interference amount and interference zone are calculated.
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