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The research was financed in the framework of the project Lublin University of Technology-Regional
Excellence Initiative, funded by the Polish Ministry of Science and Higher Education (contract no. 030/RID/2018/19).
This paper presents selected numerical and experimental results of a study investigating the process of forming hollow stepped gear shafts from tubes by rotary compression. The objective of the study was to determine whether the rotary compression process is an effective method of producing hollow stepped gear shafts and to identify limitations of this manufacturing method. A theoretical analysis involved the numerical modeling of the proposed process by the finite element method (FEM). 3D simulations were performed using the commercial simulation software package Simufact Forming. The analysis involved examining the material flow pattern along with thermal and force parameters of the process. The FEM results were verified with experimental tests conducted under laboratory conditions. The experiments were performed on a machine specially designed for the rotary compression of hollow parts. Results demonstrate that it is difficult to form a stepped gear shaft in one operation. For this reason, such parts should be formed in two operations. The first operation involves the forming of a hollow stepped shaft by rotary compression, while in the second operation, a gear is formed on one of the steps of the shaft.