A multi-stage cold forging process was developed and complemented with finite element analysis (FEA) to manufacture a high-strength one-body input shaft with a long length body and no separate parts. FEA showed that the one-body input shaft was manufactured without any defects or fractures. Experiments, such as tensile, hardness, torsion, and fatigue tests, and microstructural characterization, were performed to compare the properties of the input shaft produced by the proposed method with those produced using the machining process. The ultimate tensile strength showed a 50% increase and the torque showed a 100 Nm increase, confirming that the input shaft manufactured using the proposed process is superior to that processed using the machining process. Thus, this study provides a proof-of-concept for the design and development of a multi-stage cold forging process to manufacture a one-body input shaft with improved mechanical properties and material recovery rate.

Tungsten carbide-cobalt (WC-Co) alloys have various mechanical properties according to their Co content and manufacturing method. High-strength materials such as WC-Co alloys are usually manufactured using various sintering methods. In this study, WC-Co was compared according to the Co content and manufacturing method using the sinter-hot isostatic pressing process. Furthermore, an additional test was performed to investigate the effect of post-hot isostatic pressing (HIP) treatment on the mechanical properties. To compare tensile strength, threaded end and shoulder end specimens are generally applied in axial tensile testing with hard metals. However, it is extremely difficult to shape WC-Co by machining. A tensile testing jig for a shoulder end specimen is, therefore, proposed. Tensile tests were conducted using the proposed jig, and microstructure, hardness, and impact tests were carried out to compare the mechanical properties. The microstructure evolution was obtained by decreasing the Co content and applying the HIP treatment, resulting in changes in Young’s modulus and strength. The results indicated that the proposed jig of the axial tensile test could be applied to the extremely hard WC-Co, and the mechanical properties of WC-Co could be modified by the Co content and HIP treatment control.

In this study, the characteristics of the SKD61 material used for the stem of an extruder were analyzed through structural analysis, tensile testing, and fatigue testing. The extruder works by pushing a cylindrical billet into a die with a stem to reduce its cross-sectional area and increase its length, and it is currently used to extrude complex and diverse shapes of products in the field of plastic deformation processes. Finite element analysis was used to determine the maximum stress on the stem, which was found to be 1152 MPa, lower than the yield strength of 1325 MPa obtained from tensile testing. Fatigue testing was conducted using the stress–life (S–N) method, considering the characteristics of the stem, and statistical fatigue testing was employed to create an S–N curve. The predicted minimum fatigue life of the stem at room temperature was 424,998 cycles at the location with the highest stress, and the fatigue life decreased with increasing temperature. Overall, this study provides useful information for predicting the fatigue life of extruder stems and improving their durability.