A drive axle shaft and method for making the same are provided. A tubular blank is inserted in a first die including an orifice. The tubular blank is extruded through the orifice to form an elongate tubular body with a longitudinal axis. A first longitudinal end of the tubular body is heated. The tubular body is inserted into a bore in a support apparatus. The support apparatus defines a second die at one end surrounding the bore, and the first longitudinal end of the tubular body projects outwardly from the bore. A third die comprises a mandrel configured to be received within the tubular body. A wheel flange is formed by moving at least one of the support apparatus and the third die toward the other of the support apparatus and the third die to deform the first longitudinal end of the tubular body between the second and third dies.

A hollow axle shaft for transmitting rotational motion from a prime mover to a wheel of a vehicle comprises an elongated member. The elongated member extends along an axis between a first end and a second end. The hollow axle shaft further comprises a flange at the first end and extending radially away from the axis for receiving the wheel. The flange is integral with the elongated member. A method of manufacturing the hollow axle shaft comprises the step of providing the elongated member comprising a material and defining a bore extending along the axis between the first and second ends, and the step of forming the flange with the material at the first end.

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 hollow wind turbine main shaft and a profiling forging process and a use thereof are provided. The profiling forging process includes: step S1: smelting alloying elements according to a formula to obtain a melt, casting the melt to obtain an ingot, and hot-feeding the ingot; step S2: reheating the ingot hot-fed in the step S1, followed by primary drawing-out, primary upsetting, secondary drawing-out, and secondary upsetting to obtain a forged ingot; step S3: reheating the forged ingot, followed by punching to obtain a punched forging; step S4: reheating the punched forging, and performing drawing-out and rounding on a shaft body of the punched forging to obtain a finished forging; and step S5: placing the finished forging into a thermal insulation barrel for slow cooling, and air-cooling the finished forging to a room temperature to obtain the hollow wind turbine main shaft.