Stamper uses servo press to final-form spline

A stamping manufacturer to the automotive industry used its Komatsu servo press for a unique application—final forming a machined shaft into a high-end splined component on the press instead of machining it.

The manufacturer used the servo press’s step/vibration mode to perform the intricate forming. Starting only 3 inches off the bottom of the stroke, the ram goes up and down multiple times in one stroke, applying full, consistent energy. The downward motions form the shape, and the upward motions allow the metal to reflow.

Because the ram does not push down on the metal in one aggressive stroke, the metal is allowed to flow in a path of least resistance—even upward on the upstroke. As a result, the splined shaft final-formed on a servo press is actually slightly taller than the original machined blank.

This final forming could not be performed on a standard mechanical press without “mushrooming” the part.

Using the servo press, the supplier was able to achieve the same tolerances as machining. The press is equipped with a linear scale that holds accuracy level in microns.

A splined shaft is engineered to last longer than a shaft with a simple key that is inserted into a similarly sized, machined keyway. A spline has multiple contact connections rather than just one as does a key. By using its servo press, the manufacturer was able to supply a superior part to its customer without secondary operations.

Using the press expedited throughput because stamping the final details of the shaft into a spline in the servo press was faster than machining them.

Komatsupress.com