A machine for spin-forming a solid disk blank having a center axial bore into a pulley configuration exhibiting an outer peripheral pulley groove and a flanged bore bearing retainer. Die members maintain the disk blank on the machine axes by clamping the disk blank between an upper and lower die members. A power source affects rotational motion of at least one of the die members to affect rotation of the disk blank. A splitting tool, a swaging tool, and a splitting-swaging tool are moveable for engaging the disk blank and affecting splitting and swaging of the bore and peripheral edge. A rotatable inner tool spindle comprises the splitting-swaging tool connected thereto and is movable horizontally such that the tool splits and swages the center axial bore. A power source affects rotational motion of the spindle and thus the rotational motion of the splitting-swaging tool.

A method for producing a formed body includes providing a round or pre-formed semi-finished product of a steel material, and heating the semi-finished product at least in regions to a first temperature. The method further includes forming a hub on the semi-finished product warm at least in regions, for generating a preform having an upper geometric element. The method further includes heating or re-heating the preform having an upper geometric element at least in regions to a second temperature, and forming a bell on the preform having an upper geometric element warm at least in regions, for generating a preform having an upper and at least one lower geometric element. The method further includes heating or re-heating the preform at least in regions to a third temperature, and profiling the preform warm at least in regions for generating a formed body in a third operative step.

A method of manufacturing a railroad car tank head includes the steps of providing a circular blank of steel plate material, cold-forming the circular blank to form an intermediate ellipsoidal dish, cold-forming a peripheral flange region of the intermediate ellipsoidal dish to form a flanged ellipsoidal dish, and heat treating the flanged ellipsoidal dish. The heat treatment may be either a thermal stress relieving heat treatment or a normalizing heat treatment. The two cold-forming steps may be carried out at room temperature. The present invention provides a method of making a railroad car tank head that is more efficient than prior methods, avoids the challenges of hot-forming and single-stage cold-forming, is easily adaptable to different tank head diameters using the same forming equipment, and yields a railroad car tank head that meets safety standards.

A spin forming process and apparatus is disclosed. A workpiece (e.g. sheet metal) is rotated with respect to a forming roller which bears against one of the outer and inner surfaces of the workpiece to deform the workpiece towards a required shape. First and second support rollers bears against the opposite surface of the workpiece. Computer control of the positions of the forming roller and the first and second support rollers allow non-axisymmetric shapes to be manufactured by spin-forming.

A new method of manufacturing a railroad car tank head having the steps of providing a circular blank of steel plate material, cold-forming the circular blank to form an intermediate ellipsoidal dish, cold-forming a peripheral flange region of the intermediate ellipsoidal dish to form a flanged ellipsoidal dish, and heat treating the flanged ellipsoidal dish. The heat treatment may be either a thermal stress relieving heat treatment or a normalizing heat treatment. The two cold-forming steps may be carried out at room temperature. The present invention provides a method of making a railroad car tank head that is more efficient than prior methods, avoids the challenges of hot-forming and single-stage cold-forming, is easily adaptable to different tank head diameters using the same forming equipment, and yields a railroad car tank head that meets safety standards.