Talal Paracha Thesis presented to the University of Waterloo in fulfillment of the thesis requirement for the degree of Master of Applied Science in Mechanical and Mechatronics Engineering 2018.
The automotive industry has placed significant emphasis on weight reduction to achieve better fuel economy while maintaining safety and quality standards. One way this can be achieved is by using forged magnesium alloys due to their high stiffness- and strength-to-weight ratios.
This FIERF supported research presents a new method for forging hollow shafts for power transmission. This method consists of three main operations; selective heating of a tubular workpiece, upsetting of the workpiece to produce a solid section in the heated section and, flanging or heading of the hot solid portion of the tubular workpiece. FEA and experiments were carried out to determine the feasibility of the process.