Methodology for the design of recursively axially formed rotor shafts made of two or more combined segments

作     者：R. Kurth R. Tehel T. Päßler H. Wagner D. Beihofer 

作者机构：Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Felss Systems GmbH Dieselstraße 2 75203 Königsbach-Stein Germany 

出 版 物：《Procedia Manufacturing》 

年 卷 期：2019年第27卷

页      面：13-20页

主　　题：forming rotor shaft finite element method (FEM) axial forming rotary swaging joining serration 

摘      要：Electric drives are used in all industrial fields in a growing number. Whereas the rotor shafts used in the area of machinery and plant engineering are designed as solids, the shafts mainly used in the field of automotive industry are hollow shafts focusing on the lightweight potential and the improvement of motor characteristics. This paper describes a shaft design consisting of two or more segments manufactured by a new combination of certain cold forming processes before joining. This design enables higher flexibility of variants as well as optimization of production efficiency and logistic chains. Thus, the joint zone design is a special serration with a helix angle in order to reach a high robustness of the shaft. A detailed FEM simulation of the elastoplastic behavior of the joint zone and the mechanical characteristics of the complete shaft leads to an evaluation of possible applications of this joint geometry and the corresponding manufacturing process. Based on experimental investigations, the simulations have been validated successfully. An empirical model designed by regression analysis of further simulation results is used to propose a design methodology for the identification of design parameters of the assembled shaft and the joint zone as well. These parameters can be used for planning the forming processes and the blank geometry.