Abstract: A method for manufacturing a forged article, capable of improving the durability of a die for forging is provided. The method, includes forging a steel material, by using a die, by spraying or applying a water-soluble polymer lubricant containing 0.01 to 0.98 mass % of a water-soluble sulfate onto a working surface of the die, the die being made of a raw material having a constituent composition of by mass %, of 0.4 to 0.7% of C, 1.0% or less of Si, 1.0% or less of Mn, 4.0 to 6.0% of Cr, 2.0 to 4.0% of (Mo+½W), 0.5 to 2.5% of (V+Nb), 0 to 1.0% of Ni, 0 to 5.0% of Co, 0.02% or less of N, and a remnant composed of Fe and impurities, and having hardness of 55 to 60 HRC, and the die including a nitrided layer or a nitrosulfidized layer on the working surface thereof.

Abstract: In a method for thickening a plastically deformable hollow body wall of a hollow body, with effective radial support of the unthickened hollow body wall on an outer supporting face of an outer mold and with effective radial support of the hollow body wall on an inner supporting face of an inner supporting body, the hollow body is acted on by a compressive force by two application members at application points by moving the application members towards one another in the axial direction with a compressing movement. The application points on the hollow body are distanced from one another in the axial direction. An expansion space of the outer mold is arranged between the application points.

Abstract: A method for producing friction discs for a, in particular radial, dual clutch, includes the following steps: providing a first disc ring with a first inner diameter, providing a second disc ring with a second outer diameter, wherein the second outer diameter is smaller than the first inner diameter, and processing the first disc ring and the second disc ring in a tool for producing the friction discs. The second disc ring is arranged within the first disc ring, and the second and the first disc rings are processed in the tool together.

Abstract: A method of forming a shaped steel object, includes cutting a blank from an alloy composition. The alloy composition includes 0.1-1 wt. % carbon, 0.1-3 wt. % manganese, 0.1-3 wt. % silicon, 1-10 wt. % aluminum, and a balance being iron. The method also includes heating the blank to a temperature above a temperature at which austenite begins to form to generate a heated blank, transferring the heated blank to a die, forming the heated blank into a predetermined shape defined by the die to generate a shaped steel object, and decreasing the temperature of the shaped steel object to ambient temperature. The heating is performed under an atmosphere comprising at least one of an inert gas, a carbon (C)-based gas, and nitrogen (N2) gas.

Abstract: A method of manufacturing an outside joint member, the outside joint member including a cup portion in a bottomed tubular shape and a shaft portion that is a shaft-like portion extending from a bottom portion of the cup portion and that has a spline shaft having an outer peripheral surface on which spline teeth are formed, includes forging a forming material to form a shape of the cup portion and a shape of the spline shaft on the shaft portion simultaneously using a forging die.

Abstract: A synchronizer ring (10) for synchronized manual transmissions is manufactured by forming or reshaping a flat material of metal, wherein a conical friction surface (20) is produced, into which axial grooves (24) are incorporated by chipless machining, wherein a tool is axially shifted relative to the friction surface (20) to produce the final friction surface (20). At least the friction surface (20) is vibration-ground and subsequently hardened.

Abstract: A die set for crimping operations includes first and second die members having raised areas including a plurality of knurls and character areas. The die set combining knurls and character areas on the operative areas of the die members allows a single die set to be used to condition a surface for crimping operations as well as crimping connectors and marking them with relevant indicia without having to change die sets.

Abstract: A manufacturing method and device for a drive plate that make it possible to obtain well-tensioned teeth at a ring gear portion while extending the life of a shaping die. A preferred embodiment provides a manufacturing device including: a compression punch that compresses a side wall portion of a raw material in an axial direction, the raw material including a bottom surface portion and the side wall portion which is cylindrical and provided to extend upright from an outer peripheral end portion of the bottom surface portion. A compression die disposed to face the compression punch in the axial direction and having a toothed shape formed on an inner peripheral surface. The compression punch contacts the compression die, and thereafter the compression die is pushed by the compression punch to form a toothed shape on the side wall portion while moving in the axial direction.

Abstract: After molding a preliminarily molded product as a material, the preliminarily molded product is put into a full-enclosed forging die so that a product is molded with the full-enclosed forging die. A shear-drop suppressing portion for suppressing thickness reduction on a boss-portion side of an outer peripheral portion of a leading end surface of each of shaft portions of the product is formed on the preliminary leading-end surface configuring a leading end surface of each of the shaft portions of the product in the preliminarily molded product. When the preliminarily molded product is put into the full-enclosed forging die and the product is to be molded, a relief portion is formed between the leading end surface of each of the shaft portions to be molded and a cavity of the full-enclosed forging die.

Abstract: After molding a product-to-be-preliminarily-molded to form a preliminarily molded product as a material, the preliminarily molded product is put into a full-enclosed forging die so that a product is molded with the full-enclosed forging die. On a preliminary leading-end surface to be formed as a leading end surface of a shaft portion of the product formed of the preliminarily molded product, there is formed a shear-drop suppressing portion for suppressing thickness reduction on a boss-portion side of an outer peripheral portion of the leading end surface of the shaft portion of the product. At a time of putting the preliminarily molded product into the full-enclosed forging die so as to mold the product, a relief portion is formed between the leading end surface of the shaft portion to be formed and a cavity of the full-enclosed forging die.

Abstract: This invention relates to a method for manufacturing a damping shaft sleeve that includes: forging a base material into a billet that includes a cylindrical body having two opposite ends and an annular flange formed on one of the opposite ends; forging a shaft hole in the cylindrical body; inverting the base material and forming two annular grooves that are respectively indented from two opposite surfaces of the annular flange; forging the billet to form the annular flange into a bottom wall and a side wall, the bottom wall cooperating with the side wall to form an asymmetrical and helical groove; and forging the shaft hole to pass through the cylindrical body of the billet.

Abstract: A method for manufacturing a mechanical part by hot stamping, and a mold and a system thereof. The method includes: heating a steel plate blank at a predetermined heating temperature; and placing the steel plate blank into a mold of the mechanical part, and stamping the steel plate blank to form wrinkles at a rounded corner of the mold and form the mechanical part in the mold: wherein, the mold of the mechanical part includes a female mold and a male mold, a stamping gap configured to accommodate the steel plate blank is provided between the female mold and the male mold and a width of the stamping gap at the rounded corner of the mold is larger than a thickness of the wrinkles.

Abstract: A method and apparatus for forming a powder metal forging (B) includes a die set (A1D) for forming the powder metal forging (B) having a first die (A) complementary with a second die (D) in a longitudinal direction (ZC). The die set (A,D) has at least two features (10) of dimensions with a longitudinal component (10) and a lateral component (18), and at least the lateral component (18) varies along the longitudinal direction (ZC), at least one such feature (10) in each die (A,D). Each of the first die (A) and the second die (D) includes a castellated parting interface (12,13) dissecting the laterally varying internal longitudinal feature (10, 18) in the first die from the laterally varying feature (10, 18) in the second die (D). The castellation (12,13) in the dies (A,D) provides forged powder metal parts (B) with features of opposite drafts without trapping the part (B) in the dies (A,D).

Abstract: A compression limiter is disclosed that comprises an upper surface and a lower surface. The compression limiter further comprises an inner surface that defines a passageway configured to accommodate a fastener and an outer surface configured to engage a structure in which the compression limiter is placed. A first retainer projects outwardly from the outer surface and includes a first retention surface that has at least a planar portion. The first retainer further includes an undercut surface disposed inwardly from the first retention surface so as to create a corner extending in a direction with at least a component perpendicular to the longitudinal direction. A method of forming the compression limiter is also disclosed.

Abstract: The invention refers to a method and a press tool for manufacturing a separating disk adapted to be included in a disk package of a centrifuge rotor of a centrifugal separator. The separating disk extends around an axis of rotation and has a tapering shape with an inner surface and an outer surface along the axis of rotation. A blank of a material is provided. A central opening is made in the blank. The blank is positioned in a charging position by means of a projecting central portion. The blank is pressed against the first tool part having a shape corresponding to the tapering shape of the separating disk.

Abstract: The invention describes a method of compacting the surface of a sintered part (2), whereby a sintered part (2) is moved in a die (1) along an axis (3) in a pressing direction (20) through several die portions (7, 8, 9) from a first die portion (7) at a first die orifice (6) into a last die portion (9), and a wall surface (16) of each die portion (7, 8, 9) forms at least one pressing surface (18) against which a contact surface (17) formed by an external surface (12) of the sintered part (2) is pressed, and an internal contour (25) defined by the pressing surface (18) lying in a cross-section by reference to the axis (3) at least approximately corresponds to an external contour (26) defined by the contact surface (17).

Abstract: A method and a deep-drawing apparatus for the deep drawing of a metal sheet by means of a press, a table, a drawing punch, and also a drawing die and a counterpressure plate interacting with the drawing die, which together form a flow path for the metal sheet, wherein at least one drawing strip movable relative to the counterpressure plate is pushed transversely through the flow path of the metal sheet in order to deflect the metal sheet during a drawing phase (first deflection phase) and the drawing strip, for a stop phase, is pushed by a further short distance transversely through the flow path (F) (second deflection stage), wherein a deflection increased once again inhibits the flow of the metal sheet during the second deflection stage, and wherein the metal sheet is essentially plastically formed at the end of the deep-drawing operation, wherein the degree of deflection required during the first deflection stage is set by means of an interchangeable distance piece which is arranged between the counterpres

Abstract: A method of producing a metallic shell for a spark plug, including steps of preparing a first intermediate article by using a first die including a first large diameter cavity larger in diameter than a metal blank, a first small diameter cavity smaller in diameter than the metal blank, a curved tapered cavity between the first large diameter cavity and the first small diameter cavity, and an oil drain cavity between the first large diameter cavity and the tapered cavity and substantially same in diameter as the metal blank, wherein the metal blank is inserted in the first large diameter cavity and extruded to allow a configuration of the metal blank to conform to the first large diameter cavity, the oil drain cavity, the tapered cavity and the first small diameter cavity while being pressed by a punch, and preparing a second intermediate article by using a second die.

Abstract: A zoning closed-die extruding device comprises a closed female die and a male die. which is disposed in a longitudinal direction and configured to be mated with a closed cavity of the closed female die to extrude a blank. The male die comprises an extruding shaft portion and a stamp-extruding head portion, which is connected with the extruding shaft portion and disposed below the extruding shaft portion. A cross-sectional area of the stamp-extruding head portion perpendicular to a longitudinal axis of the closed female die is smaller than that of the extruding shaft portion perpendicular to the longitudinal axis of the closed female die. The male die is configured to rotate about the longitudinal axis of the closed female die so that the blank is sequentially and zonally deformed by the stamp-extruding head portion inside the closed cavity of the closed female die.

Abstract: A spline member manufacturing apparatus includes a shaving punch, a shaving die, a spline punch, and a stripper. The stripper supports a first surface of a base plate portion and an outer circumferential surface of a boss portion. The shaving punch is advanced relatively, while a material and the stripper are being pressed so that cutout portions are formed in an outer circumference portion of the base plate portion by the shaving punch and the shaving die. The shaving punch is further advanced relatively while the outer circumferential surface of the base plate portion is held by the shaving die, so that a spline portion is formed by inserting the spline punch along the inner circumferential surface of the boss portion.

Abstract: An apparatus for cold-forming a workpiece having a substantially round cross-section and an elongate body into a tube having a main portion with a substantially tetragonal cross-section and a reinforced end. The apparatus includes a die in which a received portion of the body of the workpiece is receivable and from which a preselected portion of the body extends, and a first punch adapted to bend the preselected portion radially outwardly to form a curled end. The apparatus also includes a second punch to form the curled end into a round reinforced end, and a die subassembly for forming the received portion of the body of the workpiece into the main portion of the tube having the substantially tetragonal cross-section and for forming the round reinforced end into the reinforced end of the tube.

Abstract: There is provided a production method capable of forming spiral ribs stably by reducing troubles at the time of cold drawing for forming the spiral ribs on an internally ribbed steel tube. When the internally ribbed steel tube on which a plurality of stripes of spiral ribs are formed in the tube axis direction is manufactured by inserting a plug on which a plurality of stripes of spiral grooves are formed on the outer peripheral surface thereof into the tube to be worked subjected to chemical treatment and then performing cold drawing, drawing is performed with the plug preheated to 50 to 200° C., thus forming the spiral ribs on the internal surface of a blank tube. The chemical treatment preferably includes a pickling step of removing oxided scale and rust on the tube surface, a step of forming a zinc phosphate coat on the neutralized tube surface, and a step of forming a lubricating layer on the zinc phosphate coat.

Abstract: Apparatus for pressing blanks in a coining, stamping or press forming operation includes a rotary pressing table to which the blanks are fed, a store receptacle for the blanks and a feed system for feeding the blanks dispensed from the store receptacle to the rotary pressing table. The feed system has a guide conduit into which the blanks pass following dispensing from the store receptacle and along which the blanks are urged to file one behind another to an exit from the guide conduit. The blanks pass directly from the conduit into a receiving station of the rotary pressing table.

Abstract: A forging apparatus 1A includes a swaging apparatus 2 equipped with a fixing die 10, a guide 20 having an insertion passage 22 for inserting and holding a bar-shaped raw material 5 in a buckling preventing state, and a punch 30. The raw material 5 is fixed to the fixing die 10 with the one end portion of the raw material protruded. The one end portion of the raw material 5 is inserted into the insertion passage 22 of the guide 20. Thereafter, while pressing the raw material 5 with the punch 30 in the axial direction, in a state in which an entire peripheral surface of the exposed portion 8 of the raw material 5 exposed between the guide 20 and the fixing die 10 is not restrained, the guide 20 is moved in a direction opposite to the moving direction of the punch 30 so that a length of the exposed portion 8 of the raw material 5 becomes a budding limit length or less at a cross-sectional area of the exposed portion 8 of the raw material 5.

Abstract: A method and a tool for fabricating a toothing at a three-dimensional body produced by forming and fine blanking, especially an attachment for car seat components or the like produced out of a flat strip, wherein the flat strip by forming and fine blanking in a tool is formed into a pot-shaped body with inner forms and a substantially evenly curved edge. Afterwards, a toothing is fabricated into the edge radially extending to the inner side of the body. The toothing in the edge of the pot-shaped body is exclusively produced by cutting and/or shaving with a fine blanking die and/or a shaving device, and a burr and/or shaving chips developing during cutting and/or shaving are pressed into a recess in the base of the pot-shaped body allocated to the toothing.

Abstract: The invention relates to an upsetting method for working a metal slug having a determined slenderness, characterized by the fact that the slug is at least partly positioned in the direction of its length, in an upsetting pot in a cylindrical housing provided for this purpose, and pressure is exerted on the slug in the direction of its length by means of a punch, until the slug fills the whole section of the housing, so as to reduce its slenderness, and to obtain a cylindrical slug with a section equal to that of the housing, in preparation for a forging operation. By this method, it is possible to upset slugs with large slenderness.

Abstract: The present invention relates to an improved method of forming a trailer receiver for use in connection with a trailer hitch assembly for towing trailers, campers, boats and the like. The invention relates to an improved method for forming a trailer receiver that utilizes cold forward extrusion and a tooling arrangement to efficiently and cost effectively produce custom trailer receivers.

Abstract: An upsetting method capable of executing diameter expansion of a diameter expansion scheduled portion of a raw material unevenly in a peripheral direction is provided. A guide 20 having an insertion hole 21 for receiving and holding the diameter expansion scheduled portion 2 of the raw material 1 in a buckling preventing state is prepared. A diameter expansion preventing protruded portion 22 protruded in an axial direction of the guide 20 is integrally formed at a part of a tip end portion 20a of the guide 20. The diameter expansion scheduled portion 2 of the raw material 1 secured to the fixed die 10 is inserted and held in an insertion hole 21 of the guide 20.

Abstract: A method for manufacturing a gear, wherein the gear is formed on a forging process by a die having an inner peripheral surface. A plurality of top surfaces corresponding to a bottom surface of the gear and both projected side surfaces corresponding to tooth surfaces of the gear and sandwiching the top surface connect smoothly to each other. The tooth surfaces and the bottom surface of the formed gear connect to each other smoothly. The forging process is carried out as a hot forging process in which the gear is formed by a hot forging die, or the forging process is carried out as a cold forging process in which the gear is formed by a cold forging die.

Abstract: A closed forging method for producing a forged product includes preparing as a forging material a cylindrical cast ingot that has a volume the same as the volume of a forged product and assumes a shape having an upper surface, a lower surface and a side surface and containing no angular portion; and applying pressure to the side surface of the forging material. The shape has a ratio of the lateral length of a projection profile of the forging material as viewed in the direction perpendicular to the direction of pressure application to a length of the forging material as measured in the direction of pressure application is 1 or less. The forged product obtained is a preform of an upper arm or a lower arm with a plurality of branches that is a suspension part for a vehicle or a yoke with a plurality of branches that is a joint part employed in a vehicle suspension. The preform or yoke has metal flow lines along each branch and exhibits enhanced mechanical strength.

Abstract: A high-pressure piping part includes a body structure forged in a closed space. The body structure is formed to include a main body portion formed by forward extrusion and side arm portions formed by side extrusion. The main body portion has therein a fiber flow formed along a passage, and the side arm portion has therein a fiber flow formed along the passage. Therefore, the direction in which stress is applied to the passage of the body structure by an internal pressure is approximately perpendicular to the directions of the fiber flows, thereby improving the degree of allowance of the resistance to pressure of the body structure for an injector.

Abstract: An externally splined clutch hub and method for making the same is disclosed wherein a flat circular metal preform with a central opening is provided and contacted with a single forging die to simultaneously cold forge a centrally disposed tubular neck extending outwardly from one side of the preform and simultaneously a splined annular ring at the periphery of the preform and extending outwardly from the other side of the preform wherein the tubular neck and the annular ring are coaxial.

Abstract: A method for manufacturing a universal joint yoke that exhibits good yield in terms of material utilization through obtainment of a universal joint yoke perform whose excess metal to be trimmed is diminished and whose cup portion is of uniform height, includes a forging step for forming a universal joint yoke preform from a workpiece 6 placed in a die including an upper die 103 and a lower die 65 which are to define a closed space. The forging step is performed such that, while a back pressure not lower than 0.

Abstract: A method of manufacturing an irregularly shaped forging includes heating a billet to a predetermined temperature, placing the heated billet within the cavity of a die, advancing a punch into the cavity to begin to disperse the material into a plurality of radially extending extremities of the cavity and continuing to advance the punch into the die to force a portion of the material to enter predetermined clearance zones between the punch and the die to form an irregularly shaped forging having a plurality of axially extending flash portions.

Abstract: When an actuator is operated, an upper die is displaced downwardly, pressing a lower surface of a workpiece against a forming surface. After the upper die is displaced upwardly, an ejecting member is displaced upwardly to push the workpiece upwardly by a lower die. As the workpiece is displaced upwardly, an outer circumferential surface of the workpiece is squeezed by a squeezer projecting radially inwardly from an inner circumferential surface of an outer ring.

Abstract: A die for forming a work-piece having a complex geometry includes a die insert having an interior surface that defines a first portion of the complex geometry and a retainer ring that selectively engages the die insert. The retainer ring includes a circumferential interior surface that defines a second portion of the complex geometry. A punch insert that is slidably disposed in the retainer ring and includes a surface that defines a third portion of the complex geometry.

Abstract: A method of forging a trailer receiver tube by providing a die having an inner surface defining a first portion and a second portion. Providing a hollow tube having an outer surface. Providing a punch having a body and a shaft extending therefrom sized to fit within the hollow tube. Loading the hollow tube within the first portion of the die. Inserting the punch into the hollow tube such that the body abuts an end of the hollow tube and the shaft extends therethrough. Advancing the punch and the hollow tube through the die such that a portion of the hollow tube is extruded into the second portion of the die and the outer surface of the hollow tube conforms to the inner surface of the die to thereby form the trailer receiver tube.

Abstract: A forging die for forging a cylindrical rotor having a plurality of vane-accommodating grooves which extend toward the axis of the rotor, includes an upper die; a lower die having a mold cavity in its center portion, and a plurality of vane-accommodating-groove-forming portions which protrude inward from an inner wall which defines the mold cavity; and a spacer having a plurality of shell segments for determining a shape of a side wall of the cylindrical rotor which is segmented by the vane-accommodating grooves, and a flange for joining the shell segments is disclosed. The spacer is provided in the interior of the mold cavity of the lower die. A forging production system for producing the rotor; a method for producing the rotor; and the rotor are also disclosed.

Abstract: A token is manufactured using a combination of minting or casting operations and printing operations. The token comprises a metal base material that is minted or cast to the size and shape desired including embossed or debossed areas at selected locations on the token. In selected recessed or countersunk portions of the token, there are provided thin disks of material capable of carrying printed material such as single-colored or multi-colored pictures or indicia. The imprinted disk portions of the token are covered with a first protective coating and, optionally a second protective coating, that eliminates wear and tear on the printed areas of the token. Additionally or alternatively, the entire token can be covered with an outer coating to minimize wear and tear and preserve the unique designs carried by the token.

Abstract: A token is manufactured using a combination of minting or casting operations and printing operations. The token comprises a metal base material that is minted or cast to the size and shape desired including embossed or debossed areas at selected locations on the token. In selected recessed or countersunk portions of the token, there are provided thin disks of material capable of carrying printed material such as single-colored or multi-colored pictures or indicia. The imprinted disk portions of the token are covered with a first protective coating and, optionally a second protective coating, that eliminates wear and tear on the printed areas of the token. Additionally or alternatively, the entire token can be covered with an outer coating to minimize wear and tear and preserve the unique designs carried by the token.

Abstract: A method and tool are provided for manufacturing an outer race for constant velocity joints by plastic deformation of a preform having a cavity open on one side to produce axial ball tracks and cage guide surfaces. the preform is inserted within an outer tool. An inner tool is inserted within the preform. The preform is wobble pressed with the inner tool.

Abstract: A process for cold forming the ends of metal tubes to reinforce same includes a die cavity into which the tube is placed. The die cavity includes a section with a recess having a greater diameter than the tube. The tube is placed such that a portion is left outside of the cavity and a mandrel is inserted into the tube. The mandrel includes a section that is adapted to bear against the portion of the tube outside of the cavity and to deform same. The deformation process results in the tube being folded upon itself within the recess in the cavity thereby forming a reinforcing flange at the end of the tube. The process is conducted without heating the tube.

Abstract: A hydraulic pressure control apparatus comprises a high pressure accumulator for sucking pressure oil supplied to a relief chamber of a relief valve to make changeover for the relief valve from a valve-closed state to a valve-open state when a forming load is applied to the pressure oil charged in a pressure chamber and the hydraulic pressure of the pressure oil arrives at a relief preset pressure, and a low pressure accumulator for sucking the pressure oil charged in the pressure chamber via the relief valve which is in the valve-open state.

Abstract: A device for forming components from billets having a thickness profile which is essentially symmetric to the central plane of the billet, i.e., the billet contains a thickness transition on both sides, and wherein the thickness transitions on both sided of the billet are transferred to one side of the formed such that the side of the formed component is planar. The forming surface of the forming device which faces the side of the billet that has a thickness transition in the formed state of the billet has a shape is adapted to the thickness transition to be realized, and the forming surface of the forming device which faces the side of the billet that becomes planar in the formed state is planar. Due to these measures, it is possible to transfer the thickness transitions that originally existed on both sides of the billet to one side of the billet in only one step.

Abstract: A device comprising an outer body (6) integral with a guide tube (4) defining on its own a blind ring-shaped cavity (40) axially oriented wherein a piston (3) moves guided by the guide tube (4). The guide tube (4) is produced by impact extrusion. The invention is applicable to motor vehicles.

Abstract: A hydraulic pressure control apparatus comprises a high pressure accumulator for sucking pressure oil supplied to a relief chamber of a relief valve to make changeover for the relief valve from a valve-closed state to a valve-open state when a forming load is applied to the pressure oil charged in a pressure chamber and the hydraulic pressure of the pressure oil arrives at a relief preset pressure, and a low pressure accumulator for sucking the pressure oil charged in the pressure chamber via the relief valve which is in the valve-open state.

Abstract: An apparatus to process, in particular, curved surfaces using one or more grinding or polishing tools which includes a housing (2) having a drive system (3, 20, 19, 12) powering at least one tool seat (1) particularly for a grinding or polishing tool (W) into rotation about a longitudinal axis (4). For the purpose of multi-sided pivoting displacement of the axis of rotation (4) within a predetermined angular range (&agr;), the tool seat (1) rests pivotably in a holder (5) of the housing (2), the holder (5) including a shell (7) having an outer contour in the shape of a spherical segment and being pivotably received in an inner contour of a seat (8) also in the shape of a spherical segment. The drive system (3, 20, 19, 12) includes a pivoting ball-joint (6) coupling it to the tool seat (1) in order to drive the seat into rotation in every pivoted position.

Abstract: An improved method of forging a piston and a forging die therefor. The forging die is formed from a pair of pieces which form an area where the forged material is extruded into. These pieces merge at a parting line that passes through the center of the outer edge of the forged material so as to afford some relative movement between the die pieces to avoid cracking and also to permit air to escape. Some small flash or parting line may be present in the finished material which is not objectionable and permits the attainment of the higher strength and better wear resistant piston.

Abstract: A multi-stage forming tool for densifying the outer perimeter of post-sintered powder metal preforms includes a series of axially spaced die plates having different sized die openings arranged from largest to smallest. An oversized powder metal preform it is forced by a punch through the successive die openings causing the outer perimeter material to be displaced and densified. The space between successive dies allows for elastic recovery of the preform to maximize the compressive stress imparted to the preform at each die stage. A high density, high strength powder metal component results which is suitable as a replacement for wrought components in high strength applications such as transmission gears.

Abstract: Methods and apparatuses for near net warm forging relatively small, complex shaped parts, such as automotive rocker arms, is disclosed. Die and punches are provided, which collectively have surfaces corresponding to the surfaces of the as-forged parts. Centralized workpieces, e.g., a transverse cylinders having a length-to-diameter ratio of approximately 1:1, are placed in cavities of the dies, and the punches are cycled through forging strokes to form the as-forged parts. The as-forged parts may have draft angles of 0-2.degree. and surface-to-surface transitions with radii of less than or equal to about 1mm, and may also have substantially parallel side surfaces.