This paper is about development and testing of cold rotary forging technology for manufacturing of hollow shaft flanges. Rotary forging mills with rotated die and conical roll were used for forming. Pre-machined blanks were made from pieces of welded or extruded pipes from carbon steel with 0.2 % of carbon. Design of tool-sets, sketches of blank and forged parts are presented.

The prospects of 3D printed plastic tooling in the processing of metal forming are shown. The study of the process of thin sheet, forming of aluminum 3003 ANSI, established that in this process the destruction and plastic deformation of the plastic tool does not occur. Lubrication of plastic matrices and punches were not required, as they have anti-friction properties. Computer simulation of this process in the software system "Simufact.forming" accurately reflects the force parameters, stress-state of plastic tool and the actual course of the process of forming the blank, including the spring-back of the part after forming. Technology of sheet forming with plastic tool can be recommended for single and small batch production.

Shown prospects of 3D printed plastic tooling in the processing of metal forming. The study of the process of thin sheet forming of aluminum 3003 ANSI established that in this process of destruction and plastic deformation of the plastic tool does not occur. Lubrication of plastic matrices and punches were not required, as they have anti-friction properties. Computer simulation of this process in the software system “Simufact.forming” accurately reflects the force parameters, stress-state of plastic tool and the actual course of the process of forming the blank, including the spring-back of the part after forming. Technology of sheet forming with plastic tool can be recommended for single and small batch production.

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