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Die Forging Process for Gear Couplings: High-Precision Meshing for Long-Service Torque Transmission
To meet the demands of high-speed, heavy-load power transmission, our gear couplings are manufactured using a five-heat die forging process with precise control over heating temperature and forging ratio. Through upsetting, drawing out, and final forging within the die ring, this process effectively eliminates casting defects such as shrinkage cavities and porosity while refining the grain structure. Compared to conventional free forging, our method achieves higher precision, ensuring accurate tooth-to-tooth meshing of the gear blank flange. The total forging ratio is controlled above 5, significantly enhancing the material's fatigue strength and impact resistance while effectively reducing local contact stress. Additionally, for special shaft-hub connection requirements, we have introduced non-circular turning technology to efficiently machine polygonal couplings, replacing traditional spline connections for more uniform load distribution and elimination of stress concentration points.
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