Face-gear forging method

A method of forming a billet into a face gear, the method comprising the following steps:

• providing a face gear having at least one hyperbolic surface;
• approximating the hyperbolic surface of the face gear with a ruled surface, the ruled surface comprising a plurality of zero-curvature lines which approximate the hyperbolic surface of the face gear;
• and
• forming the approximated hyperbolic surface on the billet using a wire electronic discharge apparatus, to thereby form the face gear to thereby generate a face-gear forging die.

A method of manufacturing an object from a substrate material, the material comprising the following steps:

• generating a representation of an object having a curved, hyperbolic surface by applying a plurality of straight lines to the curved, hyperbolic surface, each of the plurality of straight lines being disposed substantially entirely on the curved, hyperbolic surface of the object;
• providing a substrate material;
• and
• manufacturing the substrate material into the representation of the object, the manufactured substrate material comprising a plurality of linear surfaces which correspond to the plurality of straight lines.

A method of forming a blank into a face-gear forging die, the face-gear forging die having a hyperbolic surface, the method comprising the following steps:

• approximating the hyperbolic surface of the face-gear forging die with a ruled surface;
• providing a wire discharge apparatus;
• and
• forming the approximated hyperbolic surface on the blank using a wire electronic discharge apparatus, to thereby generate a face-gear forging die, wherein a wire of the wire discharge apparatus is passed through at least one point on the hyperbolic surface, the wire passing through the at least one point along a zero curvature orientation on the hyperbolic surface.

A method manufacturing an object from a substrate material, the material comprising the following steps:

• generating a representation of a surface of a face-gear forging die by mathematically applying a plurality of straight lines to the surface, each of the plurality of straight lines being disposed substantially entirely on the surface of the face-gear forging die;
• providing a wire discharge apparatus;
• providing a substrate material;
• and
• manufacturing the substrate material into the representation of the surface of the face-gear forging die, using the wire discharge apparatus, the manufactured substrate material comprising a plurality of linear surfaces which correspond to the plurality of straight lines.