Abstract: A rack for a steering gear includes a toothed portion with a toothing extending along a longitudinal axis, and a generally cylinder-segment-shaped back opposite the toothing and having a back radius. A method for producing such a rack includes forming a cylindrical blank with an unmachined radius between a toothed die part having a toothed mold clearance and a back die part having a back mold clearance in a die cavity. The die may have a generally cylinder-segment-shape. In an open position of the die, the blank may be inserted between the toothed mold clearance and the back mold clearance. The toothed die part and the back die part in a forging stroke for closing the cavity may then be moved in a closing direction to a closed position. The back radius of the back mold clearance may be larger than the unmachined radius of the blank.

Abstract: A rack for a steering gear may include a toothed portion that has a toothing extending along a longitudinal axis, and a generally cylinder-segment-shaped back opposite the toothing and having a back radius. A method for producing such a rack may involve forming a cylindrical blank with an unmachined radius between a toothed die part having a toothed mold clearance and a back die part having a back mold clearance in a die cavity. The die may have a generally cylinder-segment-shape. In an open position of the die, the blank may be inserted between the toothed mold clearance and the back mold clearance. The toothed die part and the back die part in a forging stroke for closing the cavity may then be moved in a closing direction to a closed position. The back radius of the back mold clearance may be larger than the unmachined radius of the blank.

Abstract: A die apparatus and method for performing a flashless forging operation to manufacture the toothed portion of a steering rack. The die apparatus includes first and second die members and at least one punch member, each having a forming surface shaped substantially as an obverse of a portion of the toothed portion. At least a portion of the forming surface of the first die member is shaped substantially as the obverse of the teeth of the rack. The first and second die members are moveable towards each other to a closed position, thereby partially forging the toothed portion from a blank placed in the die apparatus, and forming a substantially closed cavity defined by the forming surfaces. The punch member is adapted to move into the cavity once the die members are in the closed position, thereby completing the forging operation.

Abstract: A method of manufacturing a steering rack for a vehicle rack and pinion steering system. The rack comprises gear teeth and a shank that has a constant outside diameter and constant wall thickness over the majority of its length. The method comprises performing a forging operation on a tubular member with an elongate member positioned in the bore of a thickened region of the tubular member. The forging operation forms the gear teeth on the thickened region, and the elongate member is retained within the tubular member. The tubular member is made by performing a forming operation on a length of tube stock such that the outside diameter of the thickened region is smaller than the outside diameter of the shank, and the wall thickness of the thickened region is larger than the wall thickness of the shank.

Abstract: A die apparatus and method for performing a flashless forging operation to manufacture the toothed portion of a steering rack. The die apparatus includes first and second die members and at least one punch member, each having a forming surface shaped substantially as an obverse of a portion of the toothed portion. At least a portion of the forming surface of the first die member is shaped substantially as the obverse of the teeth of the rack. The first and second die members are moveable towards each other to a closed position, thereby partially forging the toothed portion from a blank placed in the die apparatus, and forming a substantially closed cavity defined by the forming surfaces. The punch member is adapted to move into the cavity once the die members are in the closed position, thereby completing the forging operation.

Abstract: A die apparatus and method for performing a flashless forging operation to manufacture the toothed portion of a steering rack. The die apparatus includes first and second die members and at least one punch member, each having a forming surface shaped substantially as the obverse of a portion of the toothed portion. At least a portion of the forming surface of the first die member is shaped substantially as the obverse of the teeth of the rack. The first and second die members are moveable towards each other to a closed position, thereby partially forging the toothed portion from a blank placed in the die apparatus, and forming a substantially closed cavity defined by the forming surfaces. The punch member is adapted to move into the cavity once the die members are in the closed position, thereby completing the forging operation.

Abstract: A method of manufacturing a steering rack for a vehicle rack and pinion steering system. The rack comprises gear teeth and a shank that has a constant outside diameter and constant wall thickness over the majority of its length. The method comprises performing a forging operation on a tubular member with an elongate member positioned in the bore of a thickened region of the tubular member. The forging operation forms the gear teeth on the thickened region, and the elongate member is retained within the tubular member. The tubular member is made by performing a forming operation on a length of tube stock such that the outside diameter of the thickened region is smaller than the outside diameter of the shank, and the wall thickness of the thickened region is larger than the wall thickness of the shank.

Abstract: A forged gear and a method of manufacture thereof. The forged gear comprises a bevel gear with a plurality of teeth, each tooth having a tip disposed between two faces and two ends, the two faces extending in a substantially longitudinal direction of the tooth, wherein the tip of each tooth has at least one substantially crowned portion between the two ends along the longitudinal direction. The method of manufacture comprises forging the gear from a blank such that during the forging operation a substantial portion of the length of each forged tooth tip does not contact the die cavity.

Abstract: A die apparatus and method for performing a flashless forging operation to manufacture the toothed portion of a steering rack. The die apparatus comprising first and second die members and at least one punch member, each having a forming surface shaped substantially as the obverse of a portion of said toothed portion, and at least a portion of the forming surface of said first die member being shaped substantially as the obverse of the teeth of said rack. Said first and second die members being moveable towards each other to a closed position thereby partially forging said toothed portion from a blank placed in said die apparatus and forming a substantially closed cavity defined by said forming surfaces, said punch member being adapted to move into said cavity, once said die members are in said closed position, thereby completing said forging operation.

Abstract: A method for forming a longitudinal component (1) with mass accumulation at each end thereof from an elongate blank. The method comprising, placing the blank in a cavity of a die means (20) having a longitudinal axis about which is disposed a plurality of movable forming elements (6, 7, 8, 9, 10, 11 etc), and at least first and second movable abutment elements spaced apart and disposed on the longitudinal axis at opposite ends of the cavity. Moving the forming elements into engagement with a central portion (2) of the blank thereby squeezing and narrowing the blank in the central portion, and urging resultant mass accumulations towards each end of the blank. Also relatively moving the first and second abutment elements (16, 17) towards each other along the longitudinal axis to engage with mass-accumulations at respective opposite ends of the cavity. This in combination with the forming elements determines the final form of the component.