Proposal of New Rotary Swaging Automation Process using 6 Step Creativity of TRIZ

Rotary swaging process is a method of forging automotive drive shafts, which has process excellence such as high accuracy, high quality, and productivity improvement of products. In this paper, in order to improve the efficiency and productivity of the rotary swaging automation process, a new 2-hammer forging method will be proposed by applying 6 step creativity of TRIZ(6SC). We will simplify the materials and hammers for high accuracy of comparative analysis of existing (3-hammer forging) and proposed (2-hammer forging) methods under the same force and boundary conditions and then performed 3D modeling by SolidWorks®. And we will analyze the simulations for the 3-hammer forging method and the 2-hammer forging method using ANSYS, an analysis software tool. Finally, we will evaluate the roundness of the shaft forged by each method through ANSYS. The proposed method and the existing method will be shown to have the same strain tendency and good roundness by the simulations. Thus the proposed 2-hammer forging method can reduce the production cost (power consumption, installation cost, installation space) and improve the efficiency in the automation process by reducing the power source, compared to the 3-hammer forging method.