Abstract
The die profile for extrusion of a spur gear section through a continuously curved die is described by a parametric form in the cylindrical coordinate system using a blending function and Fourier series expansion. A finite element analysis is made for steady state three-dimensional extrusion of a spur gear section. The distribution of stress and strain components is determined. In treating the incompressibility, the penalty constraint method based on the rigid-plastic material model is used. The initial estimate for the initial velocity field is obtained from the assumption of linear viscous material. The work hardening effect is considered by integrating the effective strain rate along each streamline through interpolation by the least-square method. The elastic deformation of the die has been computed by the elastic finite element analysis. It is shown that the computer aided analysis and design of the extrusion process could help to achieve more precise production of gears with improved productivity.