Magendran, G., "Alternate Manufacturing Process for Automotive Input Shafts," SAE Technical Paper 2017-01-5013, 2017.
The input shafts are conventionally developed through Hot forging route. Considering upcoming new technologies the same part was developed through cold forging route which resulting in better Mechanical properties than existing hot forging process. It has added benefit of cost as well as environmental friendly.Generally, the part like Input shaft which having gear teeth, splines etc., will be manufactured through Hot forging process due to degree of deformation, availability of press capacity, diameter variations etc., This process consumes more energy in terms of electricity for heating the bar and also creates pollution to the atmosphere.Automotive input shaft design modified to accommodate cold forging process route to develop the shaft with press capacity of 2500T which gives considerable benefit in terms of mechanical and metallurgical Properties, close dimensional tolerances, less machining time, higher material yield when compared to hot forging and metal cutting operation.Input shaft was subjected to combination of torsional and bending load during application which required hardened case and toughened core. These properties can be achieved by Heat treatment (carburizing) process. Cold forged part also equally compatible for subsequent processes. This manufacturing was implemented and achieved remarkable cost saving and environmental friendly.