A drive axle shaft and method for making the same are provided. The drive axle shaft includes an elongate tubular body and a wheel flange. The elongate tubular body has a longitudinal axis and comprises a first end portion and a second end. The second end is configured to be coupled to a side gear in a differential. The wheel flange is disposed at the first end portion and is configured to support a vehicle wheel. The elongate tubular body and the wheel flange are formed as a unitary body without any weld therebetween.
B21K 1/06 - Making machine elements axles or shafts
B21C 1/18 - Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes from stock of limited length
B21C 1/24 - Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes specially adapted for making tubular articles by means of mandrels
A lightweight drive axle includes an elongate, tubular body having a first longitudinal end configured for coupling to a side gear in a differential and a second longitudinal end configured to support a vehicle wheel. The shaft further includes a screw disposed at the first longitudinal end of the body. The screw comprise a shank configured to be received within a bore in the body and a head having first and second portions. The first portion is disposed at one longitudinal end of the screw, has a first diameter and is spaced from the first longitudinal end of the body. The second portion is disposed between the first portion and the shank and has a second diameter less than the first diameter such that the first longitudinal end of the body and the first and second portions of the head define a groove configured to receive a shaft retainer.
F16D 1/06 - Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end
A drive axle shaft and method for making the same are provided. A tubular blank is inserted in a first die including an orifice. The tubular blank is extruded through the orifice to form an elongate tubular body with a longitudinal axis. A first longitudinal end of the tubular body is heated. The tubular body is inserted into a bore in a support apparatus. The support apparatus defines a second die at one end surrounding the bore, and the first longitudinal end of the tubular body projects outwardly from the bore. A third die comprises a mandrel configured to be received within the tubular body. A wheel flange is formed by moving at least one of the support apparatus and the third die toward the other of the support apparatus and the third die to deform the first longitudinal end of the tubular body between the second and third dies.
B21K 1/06 - Making machine elements axles or shafts
B21C 1/18 - Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes from stock of limited length
B21C 1/24 - Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes specially adapted for making tubular articles by means of mandrels
4.
Method for forming a variable wall light weight axle shaft with friction welded flange
A method for forming a lightweight axle shaft is provided. A first tubular blank is inserted in a die defining an extrusion throat at one end. A tool is inserted into the die having a mandrel with portions of increasing diameter. The tool is moved towards the outlet end of the die to partially extrude the blank through the extrusion throat and form a hollow axle shaft having a variable inner diameter based on the varying diameter of the mandrel. The tool is then removed and a second tubular blank is inserted and placed in engagement with the first blank. The tool, or a different tool, is inserted into the die and again moved towards the outlet end of the die to complete extrusion of the first blank and produce a shaft having diameters at each end that are less than the diameter of an intermediate portion of the shaft.
B21K 1/06 - Making machine elements axles or shafts
B21C 1/18 - Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes from stock of limited length
B21C 1/24 - Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes specially adapted for making tubular articles by means of mandrels
A method for manufacturing a one-piece axle tube housing with localized sections of increased wall thickness includes providing a tube blank, inserting a mandrel having a reduced diameter profile, passing the tube through an extrusion die to conform the tube to the shape of the mandrel; and extraction of the mandrel from the tube to cause outward deformation of the tube at specific locations. A further reducing step may be used to form the final desired profile, including reduced inner and outer diameters along sections of the axle tube housing.
A method for manufacturing a one-piece axle tube housing with localized sections of increased wall thickness includes providing a tube blank, inserting a mandrel having a reduced diameter profile, passing the tube through an extrusion die to conform the tube to the shape of the mandrel; and extraction of the mandrel from the tube to cause outward deformation of the tube at specific locations. A further reducing step may be used to form the final desired profile, including reduced inner and outer diameters along sections of the axle tube housing.
An extruded, tubular vehicle axle for front and rear wheel applications, is formed with integral, radially outwardly extending ribs, at the radial top and bottom dead centers of the axle, and continuously extending longitudinally along substantially the entire length of the axle parallel to the axis of the axle. The opposite end portions of the axle are snugly inserted within corresponding sockets formed, for example, in a vehicle axle yoke or carrier or housing, which sockets are provided with internal grooves for snugly receiving the ribs at the respective end portions. The exterior wall surface of the axle is substantially uniform in cross-section. The interior wall surface of the axle tube may vary, at pre-selected locations, to increase or decrease the wall thicknesses at such locations. The axle resists rotation relative to the sockets, under extreme torsional loads, and resists longitudinal bending or flexing, while being of relatively light weight.
A method for manufacturing a one piece axle tube housing with an integral spindle includes providing a tube blank, providing the blank with a region of increased thickness, inserting a mandrel having a reduced diameter profile, passing a reducing die over the tube to conform the tube to the shape of the mandrel; and extraction of the mandrel from the tube to cause outward deformation of the tube at specific locations. A further swaging step may be used to form the final spindle structure.
B21C 1/24 - Metal drawing by machines or apparatus in which the drawing action is effected by means other than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, rods or tubes specially adapted for making tubular articles by means of mandrels
B21C 3/06 - DiesSelection of material thereforCleaning thereof with adjustable section
B21C 37/30 - Finishing tubes, e.g. sizing, burnishing
9.
Method of forming axles with internally thickened wall sections
A method for forming a variable wall thickness axle or tube with internally thickened wall sections comprises extruding a tubular metal blank within an elongated die. An elongated punch pushes the blank through the die. The punch has an end abutting and pushing the blank into and through the die and an elongated portion which is spaced from the interior wall surface of the die. Movement of the punch in pushing the blank causes the blank to partially extrude forwardly through the die until stopped and then to extrude rearwardly around the punch elongated portion through the space for forming a tube. A tubular ring is then inserted within the extruded tube at a pre-determined location and is fixed in place to provide a thick, combined tube wall and ring wall, section which extends radially inwardly of the tube. A number of spaced-apart rings may be used to provide spaced-apart thickened wall sections within the tube. The rings may be pre-formed with variable wall thickness around their circumferences for varying the thicknesses of the combined wall sections around the circumference of the tube.
B23P 19/02 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes for connecting objects by press fit or for detaching same
10.
Tubular articles with varying wall thickness and method of manufacturing same
A method for manufacturing a one-piece axle tube housing with localized sections of increased wall thickness includes providing a tube blank, inserting a mandrel having a reduced diameter profile, passing the tube through an extrusion die to conform the tube to the shape of the mandrel; and extraction of the mandrel from the tube to cause outward deformation of the tube at specific locations. A further reducing step may be used to form the final desired profile, including reduced inner and outer diameters along sections of the axle tube housing.
patents