Abstract: This paper presents theoretical analysis of unconventional forging process of hollowed shaft from Ti-6Al-4V alloy in a three-slide forging press. This method in comparison with other metal forming methods allows for obtaining of hollowed products. The designed process is verified theoretically by means of numerical simulations based on finite element method with assumption of 3D state of strain. The following factors are considered in the analysis: material flow kinematics, strain distribution, temperature distribution and force of process. On the basis of results, it is stated that the application of designed technology allows for obtaining of a product of assumed quality. A comparison is made between material consumption in analyzed process and material consumption in typical metal forming methods, also in used at present technology of shaft manufacturing by machining only. It is stated that the application of forging in the three-slide forging press allows for a considerable decrease of manufacturing costs due to material savings and decrease of labor consumption of operations at finishing. © 2011 Shanghai Jiaotong University and Springer-Verlag Berlin Heidelberg.

Key words: die forging; finite element method; hollowed shaft; three-slide forging press