The invention sets out a method for simply producing components which are suitable for use under high loads and risks of wear and which have a core portion which consists of a metal material and a wear-resistant layer on a peripheral surface of the core portion. To this end, there is provided according to the invention a) a core portion blank which consists of the metal material and whose dimension in a first spatial direction is greater than the desired finished dimension of the core portion of the component in the relevant spatial direction and whose dimension in a second spatial direction is smaller than the desired finished dimension of the core portion of the component in this second spatial direction; b) there is applied a material which forms the wear-resistant layer to the peripheral surface in such a manner that the material and the core portion blank form a stable composite body; and c) the composite body is shaped to form the component by the composite body being extended in the direction of the second spatial direction and being compressed in the direction of the first spatial direction until the dimensions thereof in the spatial directions at least correspond to the desired finished dimensions of the component in these spatial directions and the wear-resistant material is present on a peripheral surface of the component. Optionally, finishing processing of the component may follow.

A forging method for a shaft member includes preforming at least one of a plurality of enlarged diameter portions to obtain a semi-finished member, and forming a remainder of the enlarged diameter portions in the semi-finished member using a mold. The mold includes a punch, split dies, and a workpiece receiving member. The forming of the remainder of the enlarged diameter portions includes allowing the semi-finished member having the at least one of the enlarged diameter portions to be placed on the workpiece receiving member, cramping the semi-finished member in its radial direction by closing the split dies, and filling the semi-finished member into forming surfaces of the split dies by the pressure applied by the punch under the state in which the semi-finished member is cramped.

A forging method for a shaft member includes preforming at least one of a plurality of enlarged diameter portions to obtain a semi-finished member, and forming a remainder of the enlarged diameter portions in the semi-finished member using a mold. The mold includes a punch, split dies, and a workpiece receiving member. The forming of the remainder of the enlarged diameter portions includes allowing the semi-finished member having the at least one of the enlarged diameter portions to be placed on the workpiece receiving member, cramping the semi-finished member in its radial direction by closing the split dies, and filling the semi-finished member into forming surfaces of the split dies by the pressure applied by the punch under the state in which the semi-finished member is cramped.

Provided are a hollow drive shaft and a method for manufacturing the same in which a concentrated load to a weak point which may be occurred by differences of sectional thicknesses and outer diameters of the shaft is dispersed so that the strength may be uniform throughout the whole length of the drive shaft. The hollow drive shaft includes: one or more small-diameter portion having a hollow shape; and a large-diameter portion which is disposed in a vicinity of the small-diameter portion and has an outer diameter relatively greater than the small-diameter portion. A sectional thickness of the large-diameter portion is less than a sectional thickness of the small-diameter portion, and a first sectional portion from an outer surface to a point corresponding to 35% to 60% of a sectional thickness of the large-diameter portion is carburized to have a first hardness.

A drive shaft for motor vehicles comprises shaft portions arranged one after the other in s longitudinal direction of the drive shaft. One shaft portion is a tubular shaft portion having a large cross section and another shaft portion having a cross section that is smaller than the tubular shaft portion having a large cross section. A transition region having a region wall is provided between the tubular shaft portion and the shaft portion having the smaller cross section. If the drive shaft is compressed in the event of a crash, the shaft portion having the smaller cross section is pushed into the tubular shaft portion having the large cross section by an insertion length, thus deforming or breaking the region wall of the transition region.

A method of manufacturing an end piece for a camshaft may include forming a shape of an end piece to be coupled to a camshaft by compacting steel and powder in a net-shape manner and by sintering steel and a powder compact that are preassembled to each other.

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.

A method of making a shaft includes: forming a shaft portion by applying drawing to a first region, of a columnar material made of steel, extending from a predetermined position in an axial direction to an end on a first side in the axial direction, to form a shaft portion, and to form a tapered portion between the shaft portion and a second region, of the columnar material, extending from the predetermined position to an end of the columnar material on a second side in the axial direction, and having an outside diameter increased as the tapered portion extends from the shaft portion side toward the second region side; and forming a head portion by applying plastic forming to the second region and the tapered portion.

The present invention discloses a swaging die holder for the flexible shaft operations. In the preferred embodiment, the swaging die holder comprises of an elliptical die holder slot, a stress relief slot, a radius curve, a recess and an insert. The die holder slot at top of the die holder allows each die holder to mount to the machine. The insert is adapted through the recess at the bottom of each die holder and designed to produce the different output profiles at the end of the flexible shaft. The insert is made of HSS material with cobalt content to achieve optimal life. The insert is further re-grinded or re-sharpened for same or other profile applications of the flexible shaft.

The present invention discloses a swaging die holder for the flexible shaft operations. In the preferred embodiment, the swaging die holder comprises of an elliptical die holder slot, a stress relief slot, a radius curve, a recess and an insert. The die holder slot at top of the die holder allows each die holder to mount to the machine. The insert is adapted through the recess at the bottom of each die holder and designed to produce the different output profiles at the end of the flexible shaft. The insert is made of HSS material with cobalt content to achieve optimal life. The insert is further re-grinded or re-sharpened for same or other profile applications of the flexible shaft.