Forging a big shaft

[Kallsme´n]

Here is a series of pictures how to forge a big shaft to Volvo Powertrain transmissions from a 170mm rounbar, and a lengt och 160mm.















The time it tok to forge the shaft is about 8-9minutes
Any questions?

Kallsme´n

[T-Gold]

Amazing Simply amazing. Was that all in one heat?

[Kallsme´n]

Yes, tha was done in one heat, but you have to hurry a bit so the steel dont lose it´s heat to much. :lol:

Kallsme´n

[scrapman1077]

No safty glasses !!! Shame on you.

[HWooldridge]

How many of these do you make for Volvo? Is it for research purposes or in production quantities?

[Ed Thomas]

Hi, Roger. Do you do the machining afterward? What is the steel type? Did you have an original pattern to make the swages? Or did you make the first one yourself to make the swages? Which hammer is that one?

I like your pictures of transferring control of the tongs. You obviously work well together.

Are your forges gas or oil? (They look like gas)

Thanks again for sharing.

[mike-hr]

You do amazing work. Thank you for posting pictures of the things you make. Please keep posting pictures and don't ever leave us!

[Strine]

I get the gist. Start with a whopping great piece of hot stuff, get it under a whopping great hammer with the aid of whopping great pairs of tongs and let it rip. Eh presto a shaft.

I agree with comments re the saftey glasses...and for "Volvo" of all manufacturers :wink: Are the parking lights on the hammer kept on day and night?

And I totally concur with comments about the nature of the work. Jolly well done...keep up the good work and the posts. Great stuff...love to see more

[Ten Hammers]

I wish to thank you for the pics of your shop and for taking the time out of your day to post this. Your knowledge is very useful and well recieved here in my small production shop. Perhaps I can return the favor sometime. Welcome aboard.

Steve ( Ten Hammers ) O'Grady
Leprechaun Forge
Bloomfield, Iowa U.S.A.

[Kallsme´n]

Hello folks

This is only for the prototype workshop at Volvo Powertrain.
We do about 30 pices of this type and year, so it´s not a big product.
But we do allot of other things to Volvo prototype workshop here in Sweden.
We allso do alot of hancrafted pieces to gearboxes for STCC, BTCC, WRC rally cars, and allso formula one cars, in the same way as the big shaft,
but still in small special series.

The material we use for this is Volvos own material called V-2525-70, it´S the same group as USA 8620,5115, and euronorm 18crnimo7.

Volvo send me a blueprin of the finished detail and I draw a proposal forged detail back and than they look at the proposal and say, OK.

I dont do any machining of anyting I forged to volvo, they do all the tempering, hardening, machining and so on, I only do the forging.

When I make the Swages ( the specialtool for the middle section) i machine a copy of my blueprint forge proposal.
Than I take two pieces of material hwo will fit to make the upper and the lower swages, heat them up, and put the machined part between, and tha strike it between the hammer dies.
Usually i have to warm the swages 2-3 times untill it finished.
Than i grind pretty big radius in the swages, bacause otherwise the shaft will get stuck in the swages.

I make all my tools by myself,swages, tongs,punches,..........

The hammer i forge this shaft in is my biggest hammer, a Beche´ 500kilogram hammer.

The oven is burning with diseloil.

I hope you understad this, or at lesat a little bit of it.

Kallsme´n