August 2019 Volume 1

FORGING RESEARCH

Report No. F/MAE/NG/-2019-1 Development of a Manufacturing Process for High-Power-Density Hollow Shafts Submitted to FIERF by Hao Pang, Research Assistant Gracious Ngaile, Professor North Carolina State University Department of Mechanical and Aerospace Engineering Advanced Metal Forming and Tribology Laboratory (AMTL) May, 2019 For Restricted Distribution Only (This report is an advanced copy subject to modification and is distributed only to the AMTL Members. Approval must be requested from the Lab Authority prior to distribution to other organizations or individuals) FOREWORD This document has been prepared by the Advanced Metal Forming and Tribology Laboratory in the Department of Mechanical and Aerospace Engineering at North Carolina State University. The research focus of this Lab includes manufacturing process modeling and optimization, triboscience and tribotechnology, tool design, and computational tools. In addition to conducting industry relevant engineering research, the Lab has the objectives a) establish close cooperation between industry and the university, b) train students, and c) transfer the research results to interested companies. This report, entitled “Development of a Manufacturing Process for High-Power-Density Hollow Shafts”, presents a novel differential heating-based forging process for hollow axle shaft, main shaft, pinion gear shaft and lay-shaft. This process is evaluated in terms of formability, forming load and dimensional accuracy with FEA simulations. Feasibility of this process is also experimentally verified by forging a laboratory scale hollow axle shaft. For further information, contact Dr. Gracious Ngaile, at the Department of Mechanical &Aerospace Engineering, North Carolina State University, 911Oval Drive – 3160 Engineering Building III, BOX7910, Raleigh, NC, 27695-7910, phone: 919-515-5222, email:gracious_ ngaile@ncsu.edu, webpage:http://www.mae.ncsu.edu/ngaile. Contents Contents. ...................................................................................................................................................................................................3 List of Figures.............................................................................................................................................................................................6 List of Tables............................................................................................................................................................................................ 11 Chapter 1.................................................................................................................................................................................................12 Introduction, Objectives and Approach ..................................................................................................................................................12

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