Cold forging can reduct welds

Case: Engine shaft for mobile hydraulics

This case concerns a motor shaft, used for mobile hydraulics that we manufacture.

When manufacturing power transmission components like shafts, it is crucial to maintain a high strength in the material, as transmission units constantly are exposed to temperature fluctuation, pressure and everyday wear and tear. In addition, complying with tight tolerance specifications is crucial, as even small irregularities in a transmission unit, can increase the wear, and even damage the engine the component is part of.

The Manufacturing Processes

The engine shaft is manufactured in 2 cold forging operations. These 2 operations shape the subject steel rod, with both a toothing and a bottom hole to the finished product. The use of a cold forging operation provides a high material strength and enables the unit to be designed with very tight tolerances. The shaft is made of black steel, with a special alloy, that makes the material harder and stronger, so that it is suitable for hydraulic systems.

Tight tolerances and material savings

The engine shaft was previously manufactured in 2 parts, which were subsequently welded together. By using this type of process, the costumer could not obtain the same narrow tolerances as we are able to achieve today, as the engine shaft is forms from only one piece of steel rod, using of a cold forging process. In addition, the shift to a cold forging  process, has eliminated the need for welds on the finished product.

Many companies manufacture transmission units on CNC machines. However, the disadvantage of this machining methods is, that it consumes metal chips in the process. This increases the material waste. By cold forging the items, no material waste is generated, which makes the items cheaper and more environmentally friendly to produce. Read more and cold forging here