Abstract: A die apparatus for forging a steering rack from a bar. The die apparatus comprises a first and a second bolster movable towards each other, and at least one gripper adapted to grip the bar as the rack is forged. The gripper comprises first and second gripper halves carried by, and movable relative to, the first and second bolsters respectively. A gripper bias means biases the gripper halves towards each other. As the bolsters move towards each other to forge the rack, the first gripper half abuts against the first bolster, and the second gripper half abuts the second bolster.

Abstract: A die apparatus and method for performing a flashless forging operation to manufacture the toothed portion of a steering rack. The die apparatus includes first and second die members and at least one punch member, each having a forming surface shaped substantially as an obverse of a portion of the toothed portion. At least a portion of the forming surface of the first die member is shaped substantially as the obverse of the teeth of the rack. The first and second die members are moveable towards each other to a closed position, thereby partially forging the toothed portion from a blank placed in the die apparatus, and forming a substantially closed cavity defined by the forming surfaces. The punch member is adapted to move into the cavity once the die members are in the closed position, thereby completing the forging operation.

Abstract: A die apparatus and method for performing a flashless forging operation to manufacture the toothed portion of a steering rack. The die apparatus includes first and second die members and at least one punch member, each having a forming surface shaped substantially as an obverse of a portion of the toothed portion. At least a portion of the forming surface of the first die member is shaped substantially as the obverse of the teeth of the rack. The first and second die members are moveable towards each other to a closed position, thereby partially forging the toothed portion from a blank placed in the die apparatus, and forming a substantially closed cavity defined by the forming surfaces. The punch member is adapted to move into the cavity once the die members are in the closed position, thereby completing the forging operation.

Abstract: A die apparatus and method for performing a flashless forging operation to manufacture the toothed portion of a steering rack. The die apparatus includes first and second die members and at least one punch member, each having a forming surface shaped substantially as the obverse of a portion of the toothed portion. At least a portion of the forming surface of the first die member is shaped substantially as the obverse of the teeth of the rack. The first and second die members are moveable towards each other to a closed position, thereby partially forging the toothed portion from a blank placed in the die apparatus, and forming a substantially closed cavity defined by the forming surfaces. The punch member is adapted to move into the cavity once the die members are in the closed position, thereby completing the forging operation.

Abstract: A method of manufacturing a steering rack bar (6) by forging, the method comprising the steps of pacing a heated cylindrical rack bar (6) in a first forging die (15) and forging a first toothed protion (37) at one end thereof; removing the rack bar; heating the rack bar at or near the other end of said rack; and placing the other end of the rack bar in a second forging die and forging a second toothed portion (39) wherein, prior to forging the second toothed portion, the rack bar is axially and angularly aligned to a predetermined axial location and angularly orientated utilising the first toothed portion or features at or near the one end of the rack bar as a datum, and placed and held in the predetermined axial location and angular orientation prior to forging of the second toothed portion.

Abstract: A method of manufacturing a steering rack bar (6) by forging, the method comprising the steps of pacing a heated cylindrical rack bar (6) in a first forging die (15) and forging a first toothed protion (37) at one end thereof; removing the rack bar; heating the rack bar at or near the other end of said rack; and placing the other end of the rack bar in a second forging die and forging a second toothed portion (39) wherein, prior to forging the second toothed portion, the rack bar is axially and angularly aligned to a predetermined axial location and angularly orientated utilising the first toothed portion or features at or near the one end of the rack bar as a datum, and placed and held in the predetermined axial location and angular orientation prior to forging of the second toothed portion.

Abstract: A forging die for forming a steering rack portion having teeth and two longitudinally extending guide faces from a blank. The die comprising first (18) and second (19) die members and four forming elements (52, 53, 54, 55) to converge on the blank. The first forming element (52) being on the second die member (19) for forming the teeth, the second (53) and third (54) forming elements being on the first die member (18) for forming the guide faces. The fourth forming element (55) slidable relative to the first die member (18) for forming a surface of the portion and connected to a first bias means (83, 84) allowing movement of the fourth forming element (55) during forging.