Abstract: A system for forging a rack bar from a blank pipe. A blank pipe 1 is held between dies 2 and 3. Stockers 7L and 7R are arranged on respective sides of the die set. In the stockers 7L and 7R, left-handed shuttles 6L1, 6L2, 6L3, . . . 6Ln and right-handed shuttles 6R1, 6R2, 6R3 . . . 6Rn are stored. First, a left-handed presser rod 5L inserts the shuttles 6L1 to the blank pipe from the left-handed stocker 7L. Then, a right-handed presser rod 5R inserts the shuttles 6R1 to the blank pipe from the right-handed stocker 7R, causing the shuttles 6L1 to be entrained and returned to the left-handed stocker 7L. Vertical shift movement is alternately executed between the left-handed and right-handed stockers 7L and 7R, so that a shuttle of step-likely increased working height is selected for executing a working process.

Abstract: A method for forging a rack bar from a blank pipe. Prior to the rack forging process, a blank pipe is subjected to a process for obtaining an adjustment of a cross-sectional shape of the blank pipe. Such a preliminary adjustment is constructed by a swaging process for reducing an outer diameter of the blank pipe and a ironing process for obtaining a desired irregular cross-sectional shape of the blank pipe. The ironing process is such that locally thickened wall portions are obtained at length wise ends as well as tooth width ends of a rack forging die.

Abstract: Method and apparatus for producing a thin walled tubular product with thickened flange. A first stage metalworking (drawing) of a circular plate material A is done by using a first die set 22 having a conical die 24 and a drawing punch 26 is done in a manner that the end of the blank plate is remained on the conical surface 24-1 of the die, so that a semi-finished tubular product A1 with a inclined flange A1-1 is obtained. Then, a second stage metalworking (drawing) of the semi-finished tubular product A1 is done by a second die set 32 having a shaping punch 34 and a restraint die 36. The semi-finished tubular product A1 is held by the restraint die 36 and the shaping punch 34 is introduced into the semi-finished tubular product A1 for effecting a wall thickness reduction under ironing principle while forming a stepped portion.