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Updated: Jun 27, 2026
07:40
A Novel Biaxial Testing Apparatus for the Determination of Forming Limit under Hot Stamping Conditions
Published on: April 4, 2017
A Novel Metal Forming Process Based on Upsetting with Two Movable Deformation Zones Demonstrated on Railway Axle
1Faculty of Mechanical Engineering, Lublin University of Technology, 38 D Nadbystrzycka Str., 20-618 Lublin, Poland.
Materials (Basel, Switzerland)
|June 26, 2026
Summary
A novel metal forming process creates stepped shafts efficiently by upsetting with two movable zones. This technology enhances process efficiency and reduces material waste, showing promise for industrial applications like railway axles.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Mechanical Engineering
Background:
- Traditional methods for forming stepped shafts can be inefficient and lead to material waste.
- Optimizing metal flow and plastic deformation is crucial for improving manufacturing processes.
Purpose of the Study:
- To introduce and analyze a new process for forming stepped shafts using two movable deformation zones.
- To evaluate the efficiency, material consumption, and forming conditions of the novel process.
Main Methods:
- Development of a new upsetting process with two counter-moving forming sleeves.
- Finite Element Method (FEM) analysis of hot-formed C35 steel specimens.
- Evaluation of material flow, strain, stress distributions, and fracture risk using the Cockcroft-Latham integral.
Main Results:
- The new process allows simultaneous formation of multiple shaft steps, increasing efficiency.
- FEM analysis confirmed proper material flow, tool impression filling, and favorable forming conditions.
- Calculated Cockcroft-Latham integral values indicate a low risk of fracture initiation.
Conclusions:
- The presented technology offers a more efficient and material-saving method for producing stepped shafts.
- The process demonstrates potential for industrial application, with further experimental verification recommended.
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