Abstract: An extrusion assembly, which fits into a hydraulic press, includes an upper die plate and a lower die plate mounted to one another by die guide posts. A lead bar is coupled to the upper die plate at one end and to a mandrel at its other end and includes helical grooves on its surface that mate with helical protrusions on lead nuts. A die shell and insert are mounted concentrically with mandrel and receive a gear blank. As hydraulic press pushes lead bar axially toward gear blank, lead nuts impart a rotational motion to lead bar, which causes mandrel to move with a helical motion as it is pressed into and pulled out of gear blank.

Abstract: A gear rolling machine includes a pair of gear rolling dies for finish forming teeth on external gear blanks. A force sensor is mounted to the machine to monitor the amount of force applied to the gear blank by the rolling dies as one rolling die is infed toward the other during the rolling process. The sensor is electronically connected to a controller that stops the infeed when a predetermined force level is attained during the rolling process.

Abstract: An extrusion assembly, which fits into a hydraulic press, includes an upper die plate and a lower die plate mounted to one another by die guide posts. A lead bar is coupled to upper die plate at one end and a hydraulic chuck at its other end and includes helical grooves on its surface that mate with helical protrusions on lead nuts. Hydraulic chuck selectively retains a mandrel assembly. A die shell and insert are mounted concentrically with mandrel assembly and receive a gear blank. A bottom rest assembly is located below die shell and is positioned to receive mandrel assembly. An ejection assembly is positioned between bottom rest assembly and a hydraulic cylinder and includes ejector pins. As hydraulic press pushes lead bar axially through gear blank, lead nuts impart a rotational motion to lead bar, which causes mandrel to move with a helical motion as it is pressed into and through gear blank. Chuck then releases mandrel assembly onto bottom rest assembly and lead bar is retracted.

Abstract: A method is disclosed for forming helical or spur gears. The method comprises providing a die having a toothed region, positioning a first blank in the toothed region of the die, inserting second and third blanks adjacent the first blank, and applying a force to the third blank. The toothed region of the die includes die teeth projecting into an internal bore of the die, and the force is applied to the third blank to move the second blank through the die until a leading end of the third blank is generally coincidental with a minimum diameter portion of the toothed region. During the application of force to the third blank, the second blank is moved through the toothed region of the die to form external teeth in the blank, and the first blank is ejected from the toothed region.