Apart from the direct observation, the size of flash can also be
regarded as an important index to judge the die filling effect.
The maximum and minimum sizes of flash in the workpiece after
the finishing procedure, namely Lmax and Lmin (Fig. 15a), are measured
separately with the aid of the measurement tool, as given
in Table 6. Obviously, the smaller ratio i of the workpiece leads
to the larger flash, thus resulting in metal underfilling of gear
shape, which is consistent with the above analysis.
The results mentioned above confirm the great influence of
workpiece geometry on the die filling for the cold rotary forging
process of a spur bevel gear.