A drive system with full surface drive contact. The drive system tends to maximize the surface contact pattern or area at typical bit-recess reaction (drive) torque values, thereby tending to minimize bit-recess surface contact stresses, coating damage, recess ream and premature bit fatigue failure. The drive system comprises a fastener and/or bit having drive surfaces formed of either polygon involutes or a single arc construction. A punch is also provided for forming a recess in either the fastener or the bit, wherein the punch has corresponding surfaces.

A secondary battery case manufacturing method of the present disclosure includes preparing a material, forming an impact formed product by performing impact forging on the material with a die and a punch, and obtaining a complete product by applying ironing on the impact formed product.

In a forming apparatus, stationary journal dies (10U, 10B) and movable journal dies (11U, 11B) each hold and retain rough journal portions (J) of a preform blank (4) therebetween, and crank pin dies (12) contacts rough crank pin portions (P) thereof, and in this state, the movable journal dies (11U, 11B) are moved axially toward the stationary journal dies (10U, 10B) and the crank pin dies (12) are moved in the same axial direction and in an eccentric direction. Rough crank arm portions (A) are axially compressed to reduce their thickness to that of crank arms of a forged crankshaft, and the rough crank pin portions (P) are pressed in the eccentric direction to increase eccentricity to that of the crank pins of the forged crankshaft. Consequently, it is possible to form a blank for finish forging having a shape generally in agreement with the shape of the forged crankshaft.

A cycle is repeated a plurality of times, which includes a forging process for placing a material to be forged in a lower die and pressing the material to be forged in this state and then separating an upper die from the material to be forged; an elevation process for lifting the material to be forged by using an elevation device to separate the material to be forged from the lower die; a rotation process for rotating the material to be forged around its center by using a rotation device; and a lowering process for placing the material to be forged rotated by the elevation device in the lower die.

A method of manufacturing a light rotor shaft for eco-friendly vehicles is provided which includes cutting a pipe material in a specified length to provide a pipe blank and forming the pipe blank to provide a first form having the first segment on a first side. The method further includes, forming a second form having the second segment by inserting and rotating a first side of a mandrel into the first side of the first form and concurrently hammer-forging the second side of the first form to form the second segment. The rotor shaft includes a third segment formed by inserting and rotating the second side of the mandrel into the first side of the second form to form the third segment.

The present disclosure relates to a hot forging and press hardening tool, having an upper tool and a lower tool, which is able to be moved towards one another in a press stroke direction, wherein a mold cavity is formed between the upper tool and the lower tool in the closed state, and cooling channels for the passage of a cooling medium are formed in the upper tool and/or lower tool, wherein at least one cutting tool which is able to be moved relative to the upper tool is arranged on the upper tool, and the cutting tool has at least one cooling channel for temperature control and/or in that the cutting tool has a forming surface oriented in the press stroke direction and a cutting edge lying there behind in the press stroke direction and/or adjacent to the forming surface.

The present disclosure relates to a hot forging and press hardening tool, having an upper tool and a lower tool, which is able to be moved towards one another in a press stroke direction, wherein a mold cavity is formed between the upper tool and the lower tool in the closed state, and cooling channels for the passage of a cooling medium are formed in the upper tool and/or lower tool, wherein at least one cutting tool which is able to be moved relative to the upper tool is arranged on the upper tool, and the cutting tool has at least one cooling channel for temperature control and/or in that the cutting tool has a forming surface oriented in the press stroke direction and a cutting edge lying there behind in the press stroke direction and/or adjacent to the forming surface.

A processor is configured to: generate analysis meshes constituting a die model and a formed-object model; calculate a distance between the die model and the formed-object model; calculate a difference between the calculated distance and a distance between the die model and the formed-object model obtained by immediately previous analysis; when the difference is a predetermined threshold value or more, calculate an approximation line based on a predetermined number of distance history data pieces starting from a time at which the distance between the die model and the formed-object model becomes zero; when the difference is less than the predetermined threshold value, calculate an approximation line based on calculated distance history data starting from a time immediately preceding the time at which the difference is determined to be less than the predetermined threshold value; and calculate, from the approximation line, a time at which the distance becomes zero.

A processor is configured to: generate analysis meshes constituting a die model and a formed-object model; calculate a distance between the die model and the formed-object model; calculate a difference between the calculated distance and a distance between the die model and the formed-object model obtained by immediately previous analysis; when the difference is a predetermined threshold value or more, calculate an approximation line based on a predetermined number of distance history data pieces starting from a time at which the distance between the die model and the formed-object model becomes zero; when the difference is less than the predetermined threshold value, calculate an approximation line based on calculated distance history data starting from a time immediately preceding the time at which the difference is determined to be less than the predetermined threshold value; and calculate, from the approximation line, a time at which the distance becomes zero.