Forming technique for the input shaft of a vehicle gearbox

The input shaft is an important part in a vehicle gearbox. A novel compound forming technique was designed due to the special structure of an input shaft. This forming technique is named once heating and combining rolling with forging,meaning that the cylindrical billet is first heated,rolled by cross wedge rolling and forged sequentially. The input shaft was deformed by the novel technique combining cross wedge rolling with die forging. The dies of cross wedge rolling and forging were designed in this paper,and the accuracy of finite element simulation was determined compared to experimental data. A great agreement between simulated and experimental results validates the predictability of finite element simulation. Extrusion was used to form the axis fillet in the forging process to avoid folding defects. The multidiameter semi-manufacture is both the product of cross wedge rolling and the billet of die forging,so it plays an important role in the whole process. The effect of cone angle and diameter was researched by experiments to determine the optimum values of parameters. Finally,the input shaft with full teeth and no defect was formed by the novel forming technique.