Abstract: A method of forming a powder metal forging, which includes the steps of providing a preform including a sintered powder metal composition; inserting the preform in at least one part of a die set having a top die and a bottom die, at least one of the top die and the bottom die defining a helical forge form therewithin; closing the die set wherein the top die is contacting the bottom die; and compressing the preform in the forge form using an upper punch including a core rod and a lower punch, the compressing step occurring after the closing step, the compressing step resulting in a formed part having a helical outer surface. The method and apparatus of the present invention is particularly advantageous when forming a powder metal forging helical outer surface and an inner contour such as a cylindrical inside diameter.

Abstract: A method and apparatus for forming a powder metal forging (B) includes a die set (A1D) for forming the powder metal forging (B) having a first die (A) complementary with a second die (D) in a longitudinal direction (ZC). The die set (A,D) has at least two features (10) of dimensions with a longitudinal component (10) and a lateral component (18), and at least the lateral component (18) varies along the longitudinal direction (ZC), at least one such feature (10) in each die (A,D). Each of the first die (A) and the second die (D) includes a castellated parting interface (12,13) dissecting the laterally varying internal longitudinal feature (10, 18) in the first die from the laterally varying feature (10, 18) in the second die (D). The castellation (12,13) in the dies (A,D) provides forged powder metal parts (B) with features of opposite drafts without trapping the part (B) in the dies (A,D).

Abstract: A method and apparatus for forming a powder metal forging (B) includes a die set (A1D) for forming the powder metal forging (B) having a first die (A) complementary with a second die (D) in a longitudinal direction (ZC). The die set (A,D) has at least two features (10) of dimensions with a longitudinal component (10) and a lateral component (18), and at least the lateral component (18) varies along the longitudinal direction (ZC), at least one such feature (10) in each die (A,D). Each of the first die (A) and the second die (D) includes a castellated parting interface (12,13) dissecting the laterally varying internal longitudinal feature (10, 18) in the first die from the laterally varying feature (10, 18) in the second die (D). The castellation (12,13) in the dies (A,D) provides forged powder metal parts (B) with features of opposite drafts without trapping the part (B) in the dies (A,D).

Abstract: A method of forming a powder metal forging, which includes the steps of providing a preform including a sintered powder metal composition; inserting the preform in at least one part of a die set having a top die and a bottom die, at least one of the top die and the bottom die defining a helical forge form therewithin; closing the die set wherein the top die is contacting the bottom die; and compressing the preform in the forge form using an upper punch including a core rod and a lower punch, the compressing step occurring after the closing step, the compressing step resulting in a formed part having a helical outer surface. The method and apparatus of the present invention is particularly advantageous when forming a powder metal forging helical outer surface and an inner contour such as a cylindrical inside diameter.