A monobloc tubular drive shaft is designed to obtain the improved structural safety and the weight reduction of the drive shaft together. The monobloc tubular drive shaft can be manufactured from an incremental hot rotary forging process. The aim of this study was to experimentally determine conditions of an incremental hot rotary forging process for a monobloc tubular drive shaft. Induction heating experiments were performed to estimate a proper heating time of an initial workpiece in an induction heating process. Several incremental hot rotary forging experiments were carried out using a mechanical press with the designed set-up. The step distance and the step angle were chosen as controllable forming parameters. Based on the results of the experiments, the influence of forming parameters on the quality of the forged part was investigated. Finally, a forming map and a proper forming condition of the incremental hot rotary forging process were estimated.
