Abstract
The objective of the project was to develop an alternate manufacturing method for spiral bevel gears used in Army helicopters. The report covers the technical description of a program to develop high velocity forging techniques to produce spiral bevel gears to pre-grind tolerances. Initial objectives were to obtain as-forged gears with .005 inches excess material on the side of each tooth for finish grinding after the heat treating. The report includes a discussion of die design parameters, the manufacturing techniques for dies, forging parameters, dimensional checks of the forged gears, machining techniques for determining as-forged geometry and macroscopic and microscopic metallurgical data showing grain flow and micro-structure. Also included is a discussion of difficulties experienced and recommendations for future investigations.

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