Finite element analysis and experimental validation of cold forging process for pinion gear with inner helical gear

This study presents an optimized cold forging process for pinion gears with an inner helical structure, employing Finite Element Method (FEM) simulations and experimental validation. Conventional CNC machining for gear manufacturing often leads to excessive material waste, high energy consumption, and prolonged processing times. To mitigate these challenges, this research utilizes DEFORM-3D simulations to analyze forming load, material flow, and frictional effects during the cold forging process. The proposed method achieves high dimensional accuracy (JIS 6 grade) while reducing forming load and extending tool life through optimized lubrication techniques. The maximum forming load for the pinion gear was determined to be 85 tonf, and the findings indicate that the absence of lubrication increases the forming load by approximately 42.8%, highlighting the critical role of lubrication in cold forging. Furthermore, experimental validation confirmed the reliability of the FEM model, with measured tooth profile errors remaining within the acceptable tolerance range. The results of this study offer valuable insights for the automotive, aerospace, and heavy machinery industries, where high-precision and high-strength gears are essential. The optimized cold forging method enhances manufacturing efficiency, sustainability, and cost-effectiveness by minimizing material waste, reducing tool wear, and improving the feasibility of mass production.