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In applications where maintaining cross-sectional thickness is critical for the structural integrity of the rotor shaft, NETFORM can offer formed internal features where wall thickness can be held consistently throughout the shaft, even when keyways are required for laminate retention.

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NETFORM’s flowforming approach to manufacturing rotor shafts provides many options for part optimization. With the correct design and manufacturing approach, weight can be reduced and cooling performance increased, while still meeting or beating cost and weight targets.

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NETFORM’s Flowforming and Press Forming technologies help overcome the product design limitations that come with using a shaft preform designed from traditional manufacturing processes. Using NETFORM’s advanced forming processes, product engineers can achieve part consolidation, weight reduction, cooling system incorporation and cost reductions not previously possible.

Rotor shafts have evolved over recent years. Originally solid machined forgings, shafts moved to lighter weight designs through additional center drilling. This in turn evolved to hollow shafts that provide greater weight reduction. The latest step in rotor shaft evolution is to increase their function from solely supporting the laminates, to additional activities such as cooling management or integrated differential gears. NETFORM has developed novel manufacturing processes that allow the cost-efficient production of advanced rotor shafts with integral cooling and component consolidation.

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Flowforming is a cold forming process in which a set of roller tools apply pressure to a rotating workpiece over a mandrel tool to form a symmetrical part. The rollers deform the preform, forcing it against the tool (also known as a mandrel), axially lengthening and radially thinning the material.

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One key product feature is the ability to integrate cooling fins on the inside of the tube. The inside surface area of the tube increases by up to 70%, improving heat dissipation.

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In addition, the usage of a forged preform allows for the incorporation of traditionally-separate components. The key factor is having design discussions (at concept stage) with all parties involved – manufacturing, product engineering, assembly. This way the optimum design can be achieved at the lowest cost.

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NETFORM has created a hollow rotor shaft design that works well for both low and high torque applications. This advanced, light-weight rotor shaft is made up of two flowformed half shafts that are laser-welded together in the center.

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The process also allows for the incorporation of traditionally separate components into the shaft itself, such as reluctor wheels/speed sensors.