Design of Rotor Shafts optimized for Rotary Swaging

Date : 11 December, 2024   Location / Mode : Pune

INTRODUCTION

The programme is focusing on the design of rotor shafts, we will explore a comprehensive range of design options for these pivotal components, particularly significant in the realm of automotive electric drives.

We will first establish a foundational understanding of rotor shafts, explaining their defining characteristics and functional roles within the broader context of engineering applications.

We then move on to the various design methods available for rotor shafts. These include solid, welded and rotary swaged variants. Each of these approaches has its own advantages and disadvantages and requires careful consideration.

The programme also focused on the key role of material selection in achieving robust and high performance shaft designs. We will evaluate various material options and examine their mechanical properties in terms of strength, durability, and machinability. We will also look at considerations for wall thickness increase and fibre flow within the material.

One part of the training will highlight the transitional period marked by the emergence of solid and assembled, mainly welded, shafts as an interim solution to different material requirements. This lesson will highlight both the merits and challenges of their design, as well as the innovative solutions engineers devised during this period.

Armed with these insights, we will outline the design principles underlying the manufacture of cold extruded and rotary swaged rotor shafts and describe their comparative advantages and limitations compared to alternative manufacturing techniques.

Finally, we will get to know the material behaviour during cold forming in order to develop rotor shafts that are characterised by faster production rates and higher reliability in their automotive application.

The programme will be enriched by real-world case studies, illustrating the efficacy and adaptability of these design paradigms in practical settings.