Potentials of dry rotary swaging

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Rotary swaging belongs to the open die forging processes acc. to DIN 8583 part 3. The technology is widely used for the production of light weight components in the automotive industry, e.g. axle shafts and steering spindles from tubular blanks thus contributing to a sustainable and resource-efficient production technology. On the other hand large amounts of mineral oil based lubricant are currently used which fulfil important tasks for reliable process technology. Superior objective of the project dry rotary swaging is to change to dry processing and to improve the resource balance of the process significantly. To achieve the objective, it is necessary to separate the current functions of the lubricant, that means lubrication of machine and forming zone, flushing of dies and cooling of process, and to solve specifically new in each case. Due to the complexity and diversity of the task, the required partial solutions cannot be solved in one discipline alone. In the project, scientists from the field of forming technology, precision cutting technology and surface technology have to cooperate. To cope with the challenges of dry forming a combination of two approaches is intended, a structuring of the tool surface and a coating. The structuring is intended to comprise several scales; the coating is realized as a multilayer system in order to generate optimized tribological conditions in the different forming zones on the tool. The successfully development technology will be demonstrated by rotary swaging tests with materials which are of high relevance for industrial applications. The results so far confirm the chosen approaches and methods.