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Advantages:
Weight reduction:
Rotary Swaging versus con- ventional production methods generally leads to weight savings ranging from 30% to 50%.
Feasibility of one-piece designs:
The use of conventional forming methods only allows the realization of two- or multi-part designs. These must be welded later which is expensive and risky.
Near-Net-Shape-Forming:
Rotary Swaging can produce a diverse range of different forms on both, the exterior and interior of a workpiece. Due to these possibilities material savings can be made and process chains shortened
Close manufacturing tolerances:
Cold forming by Rotary Swaging using HMP equipment means: High accuracy! Exte- rior tolerances usually meet IT 7 level, interior tolerances even IT 6 when special tools are used.
High Forming ratios:
Due to its incremental tool motion usually forming ratios > 100% can be realized without annealing if suitable material properties are selected.
Application:
Mono Tubular Rotor Shaft
With the help of Rotary Swaging, it is possible to produce a tubular semi- nished product with varia- ble wall thickness so that in each cross-sectional area enough mate- rial is present to take into account the fatigue strength.
The starting material for forming
is a xed to length tube. Seamless or welded tubes can be used. To ensure optimum formability, the tube must be annealed.
With the use of an internal tool, it is possible to adapt the wall thickness in different cross sec- tions to the requirements. In addition, steep-angle transitions, tightly tolerated (IT 6) diameters and almost sharp edges can be created in this way. The objec- tive is to realize the inner shape largely by cold forming. During the subsequent machining, inner shapes produced in this way can be used as a clamping and stop surface.
The forming by rotary swaging takes place depending on the degree of complexity of the shaft in 2 to 4 process steps. The HMP modular system offers several implementation options: either on CNC-controlled single-station machines or with the help of a fully automated production line with several stations.
After cold forming, the shaft can be processed conventionally:
- Turning
- Spline forming (on HMP Axial
Forming equipment)
- Heat treatment
- Grinding
- Hard turning
Author:
Dr. Ing. Frank Müller Managing Director HMP Group
Preform, realized by cold rotary swaging
Technical Papers
Finished form, realized by turning, spline forming, heat treatment and hard working
HMP Group
Göppinger Str. 1-3 75179 Pforzheim Germany
Tel: +49 7231 3199 913 info@hmp.com www.hmp.com
ITAtube Journal No2/July 2018
31