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Abstract - Rotary swaging process is a method of forging automotive drive shafts. In this paper, in order to improve the efficiency and productivity of the rotary swaging automation process, a new 2-hammer forging method will be proposed by applying TRIZ. We will simplify the materials and hammers for high accuracy of comparative analysis of existing and proposed methods under the same boundary conditions and then performed 3D modeling by SolidWorks. And we will compare the stress trends of proposed model using ANSYS Workbench and verify the feasibility by comparing the simulation results using DEFORM. Using the proposed method can reduce the production cost and improve the efficiency in the automation process by reducing the power source, compared to the existing method.
Keywords: DEFORM, 6 Step Creativity of TRIZ(6SC), Rotary swaging process, Forging, Plastic deformation
1Introduction
Monoblock Tubular Shaft (i.e., MTS), an automotive power transmission axis, is an automobile axial part, which transfers the torque generated in an engine to wheels. The MTS moves up and down according to suspension buffers and has vehicle body joints that can change angles according to the operation of a steering system. This tubular shaft is mounted between the transmission and the differential gear box, and thus transmits power and is widely used in a front wheel drive vehicle, a rear wheel drive vehicle and a four wheel drive vehicle. [1]
Many studies in the automobile industry have been performed in various fields, such as improvement of automobile fuel efficiency, structural lightweight and improvement of engine performance for environment protection, development of filtration devices for reducing exhaust gas, development of technology for reduction of noise & vibration and thereby the improvement of passenger safety. [2]
Until recently, as methods of forming an automobile shaft, a solid shaft drawing method or friction welding method has been used, as shown in Fig. 1. The use of the solid shaft cannot be competitive in that weight lightening is required to improve fuel efficiency, and the friction welding method has a problem that safety is low because cracks may occur in friction welding portions due to vibration and impact. In addition, the method of forging a shaft using a drawing or extrusion molding method has a limitation that the amount of change...