A device and method for continuously producing an at least partly hollow shaft having a varying inner diameter includes forging tools that are arranged centrally symmetrically about a forging axis and are driven radially, a clamping chuck for holding an at least partly hollow cylindrical blank, and a counter-holder for axially supporting the blank. The counter-holder has a base and a counter-holder mandrel arranged on the base and extending axially into a central cavity in the blank. The mandrel is formed of at least two parts, wherein a first part of the counter-holder mandrel constitutes an inner part and a second part of the counter-holder mandrel constitutes an outer part surrounding the inner part. At least the outer part can be moved axially relative to the inner part.

A method for projecting a production process for producing a workpiece with a desired formation of a characteristic feature of the workpiece is implemented by a computer system. Using the method, the desired formation of the characteristic feature of the workpiece is detected and compared with formations of the characteristic feature of preceding workpieces. The formations of the characteristic feature of the preceding workpieces are stored in a formation database and a production parameter that is stored in a parameter database. When a formation of the characteristic feature of a preceding workpiece that is relevant to the desired formation of the characteristic feature is established with reference to the definition of the production parameter, the production parameter is defined for the production process for producing the workpiece with the desired formation of the characteristic feature.

A method for projecting a production process for producing a workpiece with a desired formation of a characteristic feature of the workpiece is implemented by a computer system. Using the method, the desired formation of the characteristic feature of the workpiece is detected and compared with formations of the characteristic feature of preceding workpieces. The formations of the characteristic feature of the preceding workpieces are stored in a formation database and a production parameter that is stored in a parameter database. When a formation of the characteristic feature of a preceding workpiece that is relevant to the desired formation of the characteristic feature is established with reference to the definition of the production parameter, the production parameter is defined for the production process for producing the workpiece with the desired formation of the characteristic feature.

A tool configured to form four evenly spaced indentations having an indentation radius and four evenly spaced projections about a circumference of a generally cylindrical seamless ferrule having a ferrule radius. Each projection of the four projections has a projection height equal to or less than a height threshold. The tool includes four crimping dies. Each crimping die of the four crimping dies defines a concave crimping surface having the indentation radius. The tool also includes four limiting dies. Each limiting die is located intermediate two adjacent crimping dies of the four crimping dies. Each limiting die defines a limiting surface that is configured to limit a height of each projection to the height threshold.

A tool configured to form four evenly spaced indentations having an indentation radius and four evenly spaced projections about a circumference of a generally cylindrical seamless ferrule having a ferrule radius. Each projection of the four projections has a projection height equal to or less than a height threshold. The tool includes four crimping dies. Each crimping die of the four crimping dies defines a concave crimping surface having the indentation radius. The tool also includes four limiting dies. Each limiting die is located intermediate two adjacent crimping dies of the four crimping dies. Each limiting die defines a limiting surface that is configured to limit a height of each projection to the height threshold.

The invention relates to a forging apparatus, comprising forging rams (4) that are guided in the direction of stroke and accommodate forging tools (3), and lifting drives (7) which can be driven by a shaft (10) and which are supported in a non-positive manner on an abutment (12) of the forging rams (4) held under pretension in contact on the lifting drives (7). In order to provide simple constructional conditions it is proposed that the shafts (10) of the lifting drives (7) comprise two drive cams (11) which are angularly offset by 180 in relation to each other, are centrally symmetric with respect to the shaft axis, and cooperate with the abutments (12) of the forging rams (4).

The invention relates to a forging apparatus, comprising forging rams (4) that are guided in the direction of stroke and accommodate forging tools (3), and lifting drives (7) which can be driven by a shaft (10) and which are supported in a non-positive manner on an abutment (12) of the forging rams (4) held under pretension in contact on the lifting drives (7). In order to provide simple constructional conditions it is proposed that the shafts (10) of the lifting drives (7) comprise two drive cams (11) which are angularly offset by 180 in relation to each other, are centrally symmetric with respect to the shaft axis, and cooperate with the abutments (12) of the forging rams (4).

Methods are presented for the manufacture of tubular components having complex geometries. An exemplary method includes performing three radial forging operations on a workpiece that includes a bore along a longitudinal axis extending from a first end to a second end opposite the first end. The first radial forging operation includes holding the workpiece at the second end, and radially forging at least a portion of a first region proximal to the first end of the workpiece. The second radial forging operation includes holding the workpiece at the first end, and radially forging at least a first portion of a second region of the workpiece, the second region extending from the second end to a third region adjoining the first region. The third radial forging operation includes holding the workpiece at the first end, and radially forging at least a second portion of the second region of the workpiece.

A nut integrated with a bracket and a method of manufacturing the same is provided. The method includes a pre-drawing operation that forms a reference aperture and a processing cross section in the plate material supplied between the punch and the die, forming a beading portion and piercing a center of the beading portion. A forging operation forms a pipe portion having a tube shape and processes an exterior circumferential surface of the pipe portion. A precision forging process adjusts dimensions of the pipe portion formed in the tube shape, forms a protruding end that extends on a tip surface of the pipe portion and compresses the pipe portion to remove residual burrs on a surface. A post-processing operation cuts the processing cross section to a final product shape, and forms a threaded tap on an interior circumferential surface of the pipe portion.

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.