Impact of a Splined Mandrel Geometry on Die Filling in a Cold Forging Process with Adjustable Deformation Zone

Manufacturing of hollow components with local functional internal surfaces often requires complex process routes several individual operations. By using a special cold forging an adjustable deformation zone it is possible to manufacture shafts varying wall thickness over its axial length parts just within single stroke the press. Combining this principle splined mandrel allows manufacturing tailored splines. However, impact geometry and other parameters on shape forged splines have not been investigated yet. Furthermore, underfilling phenomenon can occur outer surface shaft during specific states. In contribution, geometries their part filling / in mentioned are investigated. To determine those effects, numerical investigation has conducted. Besides mandrel, also such as die tool kinematics were considered. The numerically calculated workpiece compared ideal deviation analysis.