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This paper deals with simulation studies on surface densification of PM gears by rolling process using finite element method. The PM gear is considered as a porous continuum and analysis is performed using constitutive relations based on Gurson model for porous materials. The influence of various parameters such as initial position of mating gears, braking torque applied, friction between mating surfaces and roll stock allowance on the process have been studied. The density obtained by the process is highly influenced by the braking torque applied. The results presented provide a better understanding of the PM gear rolling process.

Formability of metals and alloys in general and aluminium alloys and steels in particular is of paramount importance in sheet metal forming in automobile industry. It is well understood that the evolution of preferred crystallographic orientation of crystallites or texture during prior thermo-mechanical processing of sheets plays an important role in determining formability. The formability of sheet is measured in terms of the Lankford parameter or the plastic strain ratio which is defined as the ratio of strain in width direction to that in the thickness direction (R = εw/εt). The variation of Lankford parameter with the rolling direction and standard and ΔR value is widely used in industry as a standard for estimating the formability of the rolled sheets.