The production method includes a first step, a second step and a third step. In the first step, a steel material is forged by dies, whereby a forged product including a rough web part and four plate-shaped rough flange parts is produced. In the second step, at least one specified rough flange part, which is at least one of the four rough flange parts, is pressed by a first die, whereby a first bent portion bending outward in an up-down direction is formed in the specified rough flange part. In the third step, the edge of the first bent portion is pressed by a second die inward in the up-down direction, whereby the edge is deformed and a second bent portion is formed. In the third step, the edge of the specified flange part is deformed while the edge is kept from deforming in a front-rear direction.

The production method includes a first step, a second step and a third step. In the first step, a steel material is forged by dies, whereby a forged product including a rough web part and four plate-shaped rough flange parts is produced. In the second step, at least one specified rough flange part, which is at least one of the four rough flange parts, is pressed by a first die, whereby a first bent portion bending outward in an up-down direction is formed in the specified rough flange part. In the third step, the edge of the first bent portion is pressed by a second die inward in the up-down direction, whereby the edge is deformed and a second bent portion is formed. In the third step, the edge of the specified flange part is deformed while the edge is kept from deforming in a front-rear direction.

A torsion bar is provided that is easy, quick, and cost effective to manufacture. The torsion bar may extend along an axis and have a first end and a second end that is spaced from the first end. The torsion bar may have an active section positioned between the first and second ends. The active section may also have a length defined along the axis. A cross-section transverse to the axis may define a contour of the torsion bar where the contour may be uniform along the length of the active section. The contour may define at least one of a polygon and a polygon-like shape.

This hollow shaft member 10 includes paired diameter-reduced sections 11 respectively formed at both shaft ends of a hollow shaft-like tubular material by performing swaging processing on both the shaft ends, and an intermediate section 12 located between the paired diameter-reduced sections, and having an outer diameter larger than an outer diameter of the paired diameter-reduced sections. Shapes of connection boundaries between the intermediate section 12 and the diameter-reduced sections 11 are formed as perpendicular step-shaped sections 13 stepped substantially perpendicular to an axial direction, and the perpendicular step-shaped sections 13 are formed by the swaging processing.

A helical pier and extension shaft, one end of which is formed with a thickened hexagonally shaped female end coupler using a hot forging process that swedges and compresses the walls of the female coupler into a thickened hexagonal configuration, with subsequent heat treatment to recover and enhance yield and tensile strength to the entire main body section and female end coupler of the helical pier and extension shafts. A corresponding hexagonally shaped male coupler may be milled and inertia friction welded to the opposite end of each extension shaft, or alternatively hot forged and internally upset as an integral homogeneous part of each extension shaft, thereby completing construction of the extension shaft with opposing corresponding male and female hexagonal couplers. The forgoing helical pier has particular benefits in applications requiring deep soil penetration and/or when using a grouted helical pier system.

A torsion bar includes a central portion extending in an axial direction about a longitudinal axis. The torsion bar also includes a first end portion having a splined outer surface, the first end portion disposed proximate a first end of the torsion bar, the first end portion spaced from the central portion with a first annular groove extending circumferentially about the torsion bar.

An embodiment includes a method for net shape forging of a large rotor shaft that includes a reduced central cylindrical section and integrally forged segments along the longitudinal length thereof. In an embodiment, the net shaped forging is produced by sequentially pressing the work piece such that a near net shaped forging of the machined work piece is produced, including upset geometries such as eccentric or concentric disks. This permits a reduction in waste material (e.g., due to the machining process) and improves the strength of the upset geometries. Other aspects are described and claimed.

An embodiment includes a method for net shape forging of a large rotor shaft that includes a reduced central cylindrical section and integrally forged segments along the longitudinal length thereof. In an embodiment, the net shaped forging is produced by sequentially pressing the work piece such that a near net shaped forging of the machined work piece is produced, including upset geometries such as eccentric or concentric disks. This permits a reduction in waste material (e.g., due to the machining process) and improves the strength of the upset geometries. Other aspects are described and claimed.

A method of assembling an electric power steering assembly includes providing a shaft that extends along a longitudinal axis between a first shaft end and a second shaft end. The method further includes extruding or drawing the shaft through a die to define a spline that extends between the first shaft end and the second shaft end. The spline includes a first tooth having a first tip. The method still further includes applying a sleeve over a portion of the spline, such that the sleeve extends from the second shaft end towards the first shaft end.

This torsion beam manufacturing method is a method for manufacturing a torsion beam which is provided with a uniformly shaped closed cross-sectional portion in which a cross section orthogonal to a longitudinal direction is a closed cross section having a substantial V-shape or a substantial U-shape with a pair of ear portions, and a shape changing portion which leads to the uniformly shaped closed cross-sectional portion and in which a shape of the closed cross section changes progressively away from the uniformly shaped closed cross-sectional portion, the torsion beam manufacturing method comprising: thickening to form a pair of thickened portions in at least the shape changing portion by pressurizing each of the pair of ear portions from outside against swelling of the pair of ear portions in a slate where both outer surfaces of each of the pair of ear portions are supported.