Systems and methods for improving backward flow forming of shafts

A method for improving backward flow forming of a material, comprising:

• mounting the material in an apparatus for backward flow forming and applying a load to a plurality of rollers forming a plastic deformation zone in the material between the plurality of rollers and a mandrel;
• advancing the plurality of rollers toward a headstock at a proximate end of the mandrel forming a work piece, wherein the work piece flows from the plastic deformation zone between the plurality of rollers and the mandrel toward a distal end of the mandrel;
• and
• coupling the work piece to a catcher at a traveling end of the work piece.

A control system for backward flow forming of shafts comprising:

• a first sensor in electronic communication with a controller, the first sensor configured to measure at least one of a tension parameter, a deflection parameter, a catcher parameter, or an apparatus parameter;
• a catcher drive system in electronic communication with the controller;
• and
• a tangible, non-transitory memory configured to communicate with the controller, the tangible, non-transitory memory having instructions stored thereon that, in response to execution by the controller, cause the controller to perform operations comprising:
• receiving, by the controller, an external command and the catcher parameter;
• and
• controlling, by the controller, the catcher drive system in response to the catcher parameter and the external command.