The paper presents a new method for manufacturing hollow shafts, where tubes are used as billet. First, the design of a specially designed forging machine for rotary compression is described. The machine is then numerically tested with regard to its strength, and the effect of elastic strains of the roll system on the quality of produced parts is determined. The machine’s strength is calculated by the finite element method using the NX Nastran program. Technological capabilities of the machine are determined, too. Next, the results of the modeling of the rotary compression process for a hollow stepped shafts by the finite element method are given. The process for manufacturing hollow shafts was modeled using the Simufact.Forming simulation program. The FEM results are then verified experimentally in the designed forging machine for rotary compression. The experimental results confirm that axisymmetric hollow shafts can be produced by the rotary compression method. It is also confirmed that numerical methods are suitable for investigating both machine design and metal forming processes.
 Z. Pater, J. Tomczak, Method for plastic forming of toothed shafts. Patent europejski nr EP2422898, (2013).
 Z. Pater, J. Tomczak, Rotary Compression of Hollow Parts by Cross Rolling. Patent europejski nr EP2422896, (2013).
 Z. Dąbrowski, M. Maksymiuk, Wały i osie. Państwowe Wydawnictwo Naukowe, Warszawa (1984).
 S. Urankar, M. Lovell, C. Morrow, K. Kawada, Establishment of failure conditions for the cross-wedge rolling of hollow shafts. Journal of Materials Processing Technology 177, 545 – 549 (2006).
 C.C. Wong, J. Lin, T.A. Dean, Effects of roller path and geometry on the flow forming of solid cylindrical components, Journal of Materials Processing Technology 167, 344 – 353 (2005).
 J. Tomczak, Z. Pater, T. Bulzak, Effect of technological parameters on the rotary compression process. Eksploatacja i Niezawodność – Maintenance and Reliability 15, 3, 279–283 (2013).
 J. Tomczak, Z. Pater, Analysis of metal forming process of a hollowed gear shaft. Metalurgija 51, 4, 497 – 500 (2012).
 J. Tomczak, Z. Pater, Agregat do obciskania obrotowego wyrobów drążonych. Polskie zgłoszenie patentowe nr P.396852, (2011).
 M. E. Niezgodziński, T. Niezgodziński, Wzory wykresy i tablice wytrzymałościowe. Wydawnictwo Naukowo-Techniczne, Warszawa (2013).
 Z. Pater, J. Tomczak, J. Bartnicki, M.R. Lovell, P.L. Menezes, Experimental and numerical analysis of helical – wedge rolling process for producing steel balls. International Journal of Machine Tools & Manufacture 67, 1 – 7 (2013).
 J. Tomczak, Z. Pater, J. Bartnicki, Skrew Rolling of Balls in Multiple Helical Impressions, Archives of Metallurgy and Materials 58, 4, 1171 – 1176 (2013).
 Z. Pater, A. Tofil, Experimental and theoretical analysis of the cross-wedge rolling process in cold forming conditions. Archives of Metallurgy and Materials 52 (2007).
 G. Jovicic, R. Nikolic, M. Zivkovic, D. Milovanovic, N. Jovicic, S. Maksimović, J. Djordjevic, An estimation of the high-pressure pipe residual life, Archives of Civil and Mechanical Engineering 13, 1, 36 – 44 (2013).
 M. Graba, Numerical verification of the limit load solutions for single edge notch specimen in tension, Archives of Civil and Mechanical Engineering, 2013, 13, 1, 45 – 56 (2013).
 Kamiński M. M., Strąkowsk M. T.: On the least squares stochastic finite element analysis of the steel skeletal towers exposed to fire, Archives of Civil and Mechanical Engineering, 13, (2), 242 – 253.
 T.T. Yu, Z.W. Gong, Numerical simulation of temperature field in heterogeneous material with the XFEM, Archives of Civil and Mechanical Engineering 13, (2), 199 – 208 (2013).