The design of shrink-fit precision gear forging dies based on strength considerations using an analytical (thick-wall cylinders) approach and the finite element method are compared. While the two methods, analytical and finite element, agree well for the dies with no irregularities (gear teeth), the finite element method predicts much higher stress values than those of the analytical approach for the dies with gear teeth. These high stresses are considerably reduced by reoptimizing the geometric parameters, such as the interference between the die and the ring.
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