Steering shaft and manufacturing method therefor

A method of manufacturing a steering shaft (1) comprising a hollow plastic metal pipe (2) having an outside diameter, one end of said pip being attached to a steering wheel and the other end of said pipe having thereon an outer sleeve (3), and energy absorbers (18,19) formed by filling a synthetic resin (17) between said pipe and said outer sleeve, said one end of said pipe having a bearing mount (7), a first nut receiving portion (95), a steering wheel receiving portion (96), and a second nut receiving portion (97);

• said method comprising the steps of
• forming annular grooves (5) in said pipe corresponding to locations of said energy absorbers by roll working;
• press working said pipe using a fixed die (2) and a first movable die (23) to form a flat portion (4) toward said other end of said pipe, and to form a two stage shaft portion (32) toward said one end of said pipe, said two stage shaft portion having a smaller diameter than said outside diameter of said pipe;
• press working said pipe using said fixed die and a second movable die (37) to shape said two stage shaft portion into a three stage shaft portion (44) having preforming dimensions smaller than said dimensions of the previous step;
• press working said pipe using said fixed die and a third movable die (51) to shape said three stage shaft portion having preforming dimensions into a three stage shaft portion (58) having intermediate forming dimensions smaller than the dimensions of the previous step;
• press working said pipe using said fixed die and a fourth movable die (65) to shape said three stage shaft portion having said intermediate forming dimensions into a four stage shaft portion (74) having dimensions smaller than the dimensions of the previous step and close to the final dimensions of said bearing mount, said first ut receiving portion, said steering wheel receiving portion, and said second nut receiving portion;
• press working said pipe using said fixed die and a fifth movable die (83) to shape said four stage shaft portion having said dimensions close to said final dimension into a four stage shaft portion (94) having said final dimensions of said bearing mount, said first nut receiving portion, said steering wheel receiving portion, and said second nut receiving portion;
• cutting off said one end of said pipe;
• forming threads on said first and second nut receiving portions;
• and
• serrating said steering wheel receiving portion;
• whereby said press working steps use the same fixed die (2) and different movable dies (23,37,51,65,83) in the different steps to form accurately and smoothly the different portions of the pipe forming the bearing mount, first nut receiving portion the steering wheel receiving portion, and the second nut receiving portion with the desired final dimensions of all portions without and added finishing steps.