Abstract
This paper examines the growing adoption of advanced numerical simulation methods by gear manufacturers seeking to enhance understanding and optimization of manufacturing processes. The industry is progressing beyond isolated analyses of individual processes toward integrated simulations of sequential manufacturing steps, including heating, ring rolling, cold forming, forging, quenching, tempering, and carburization. Manufacturers are investigating the complex interrelationships between these processes using simulation software such as DEFORM to achieve more accurate predictions of critical quality factors, including final dimensions, surface hardness, microstructure evolution, residual stresses, and distortion. This shift toward comprehensive process simulation yields significant benefits for manufacturers, including enhanced gear performance, improved final quality, optimized material utilization, and reduced production cycle times. The paper presents key numerical simulation developments, recent technological advancements, and anticipated future trends that will shape the evolution of gear manufacturing processes.
