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 - Fabrication d'éléments de machines d'arbres
B21C 1/18 - Étirage par des machines ou appareils dans lesquels l'effort de traction est produit par des moyens autres que des tambours, p. ex. par chariot mû longitudinalement tirant ou poussant le matériau de façon à former des tôles, des barres ou des tubes métalliques à partir d'un matériau d'une longueur limitée
B21C 1/24 - Étirage par des machines ou appareils dans lesquels l'effort de traction est produit par des moyens autres que des tambours, p. ex. par chariot mû longitudinalement tirant ou poussant le matériau de façon à former des tôles, des barres ou des tubes métalliques spécialement adaptés à la fabrication d'objets tubulaires au moyen de mandrins
B60B 27/06 - Moyeux adaptés pour être fixés sur l'essieu
B60B 35/14 - Essieux transmettant le couple composites ou coupés, p. ex. demi-essieuxLiaisons entre les éléments ou sections de l'essieu
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 - Accouplements pour établir une liaison rigide entre deux arbres coaxiaux ou d'autres éléments mobiles d'une machine pour montage d'un organe sur un arbre ou à l'extrémité d'un arbre
B60K 17/16 - Agencement ou montage des transmissions sur les véhicules caractérisées par la disposition, l'emplacement ou le type de mécanisme de transmission du différentiel
3.
Variable-wall light-weight axle shaft with an integral flange member and method for making the same
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 - Fabrication d'éléments de machines d'arbres
B21C 1/18 - Étirage par des machines ou appareils dans lesquels l'effort de traction est produit par des moyens autres que des tambours, p. ex. par chariot mû longitudinalement tirant ou poussant le matériau de façon à former des tôles, des barres ou des tubes métalliques à partir d'un matériau d'une longueur limitée
B21C 1/24 - Étirage par des machines ou appareils dans lesquels l'effort de traction est produit par des moyens autres que des tambours, p. ex. par chariot mû longitudinalement tirant ou poussant le matériau de façon à former des tôles, des barres ou des tubes métalliques spécialement adaptés à la fabrication d'objets tubulaires au moyen de mandrins
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.
B21C 37/16 - Fabrication de tubes à diamètres variables dans le sens de la longueur
B21C 23/08 - Fabrication de fils, de barres, de tubes
B21K 1/06 - Fabrication d'éléments de machines d'arbres
B21C 1/18 - Étirage par des machines ou appareils dans lesquels l'effort de traction est produit par des moyens autres que des tambours, p. ex. par chariot mû longitudinalement tirant ou poussant le matériau de façon à former des tôles, des barres ou des tubes métalliques à partir d'un matériau d'une longueur limitée
B21C 1/24 - Étirage par des machines ou appareils dans lesquels l'effort de traction est produit par des moyens autres que des tambours, p. ex. par chariot mû longitudinalement tirant ou poussant le matériau de façon à former des tôles, des barres ou des tubes métalliques spécialement adaptés à la fabrication d'objets tubulaires au moyen de mandrins
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 - Étirage par des machines ou appareils dans lesquels l'effort de traction est produit par des moyens autres que des tambours, p. ex. par chariot mû longitudinalement tirant ou poussant le matériau de façon à former des tôles, des barres ou des tubes métalliques spécialement adaptés à la fabrication d'objets tubulaires au moyen de mandrins
B21C 3/06 - MatricesEmploi d'un matériau spécifié pour ces filièresNettoyage de ces filières à ouverture réglable
B21C 37/30 - Finition des tubes, p. ex. calibrage, polissage
8.
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.
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