Method of manufacturing a hollow shaft having a flange at one end thereof

A method of manufacturing a hollow shaft with a disc-shaped flange at one end thereof, suitable for supporting gearing in a speed change gear box of a motor vehicle, comprising the steps of:

• preparing a disc-shaped flange member with a support shaft on one side thereof and an axial projection including a constricted portion on the other side thereof;
• providing a hollow shaft member with opposed front and back ends, the hollow shaft member having an elongate internal space arranged in the axial direction thereof;
• clamping said disc-shaped flange member in a clamp apparatus with said axial projection positioned outside of said clamp apparatus;
• engaging said axial projection into a front end portion of said hollow shaft member and simultaneously inserting a mandrel into said hollow shaft member;
• pressing said hollow shaft member in said axial direction towards said disc-shaped flange member while performing a shear spinning treatment on an outer periphery surface of said hollow shaft member from its back end towards its front end and the flange member, so as to reduce the outside diameter of said hollow shaft member in an axial direction thereof and to plastically deform the front end of the hollow shaft member to have said front end engaging the flange member;
• and
• connecting said front portion of the hollow shaft member with said constricted portion of the axial projection of the disc-shaped flange member by applying an assisting force of a caulking combination to a substantially entire length of said outer periphery surface of the hollow shaft member so as to deform the hollow shaft member by reducing the thickness thereof.