EP1539396A1 - Ensemble trompette tubulaire monobloc - Google Patents

Ensemble trompette tubulaire monobloc

Info

Publication number
EP1539396A1
EP1539396A1 EP03754509A EP03754509A EP1539396A1 EP 1539396 A1 EP1539396 A1 EP 1539396A1 EP 03754509 A EP03754509 A EP 03754509A EP 03754509 A EP03754509 A EP 03754509A EP 1539396 A1 EP1539396 A1 EP 1539396A1
Authority
EP
European Patent Office
Prior art keywords
tubular blank
segment
piece tubular
spindle
axle tube
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03754509A
Other languages
German (de)
English (en)
Inventor
Bryan P. Prucher
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
American Axle and Manufacturing Inc
Original Assignee
American Axle and Manufacturing Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/645,943 external-priority patent/US20040060385A1/en
Application filed by American Axle and Manufacturing Inc filed Critical American Axle and Manufacturing Inc
Publication of EP1539396A1 publication Critical patent/EP1539396A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B21D53/90—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards axle-housings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K21/00—Making hollow articles not covered by a single preceding sub-group
    • B21K21/12—Shaping end portions of hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/06—Making machine elements axles or shafts
    • B21K1/10—Making machine elements axles or shafts of cylindrical form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/26—Making machine elements housings or supporting parts, e.g. axle housings, engine mountings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T74/00—Machine element or mechanism
    • Y10T74/21—Elements
    • Y10T74/2186—Gear casings
    • Y10T74/2188—Axle and torque tubes

Definitions

  • the present invention generally relates to axle tube housing assemblies and, more particularly, relates to an axle tube housing being integrally formed from a one-piece member.
  • axle tube housings which generally surround and enclose the axle shafts.
  • Conventional axle tube housings are typically formed by a combination of cutting, forging, cropping, welding, and machining.
  • a conventional manufacturing method of a full-float axle tube is sequentially provided. As best seen in FIGS. 1 and 18 (step 50), the conventional method includes first cutting a thick walled tube into a first section 10 and a second section 12.
  • First section 10 is to be used to manufacture the housing body or carrier, while second section 12 is to be used to manufacture the spindle.
  • first section 10 is then extruded to form an elongated member having walls of variable thickness.
  • second section 12 is warm- formed in a two-stage progression to form the spindle blank.
  • the end of first section 10 and/or second section 12 is (are) then cropped to form an acceptable welding joint.
  • first section 10 and second section 12 are friction welded together to form an axle tube housing blank 14.
  • a plurality of welding steps are required in order to attach any necessary brackets and the like.
  • a forged weld flange 18 is pressed on to axle tube housing blank 14 at a predetermined position as shown in FIGS. 7 and 18 (step 62).
  • Forged weld flange 18 is subsequently fusion welded in position to axle tube housing blank 14.
  • the remaining axle tube brackets such as a spring seat 20 and a shock mount 22, are then conventionally welded to axle tube housing blank 14 in a predetermined position.
  • axle tube housing blank 14 is straightened as necessary.
  • axle tube housing blank 14 is then machined to provide the necessary finishing steps in the manufacturing process.
  • a spindle end 24 and a rear end 26 of axle tube housing blank 14 are faced and centered according to known techniques (steps 68, 70, and 72); spindle 12, the face of weld flange 18, and the outer diameter of rear end 26 of axle tube housing blank 14 are also turned and/or roll threaded (steps 74, 76, 78, and 80); weld flange 18 is drilled and the resultant holes deburred (step 82); and finally the bearing and seal surfaces of axle tube housing blank 14 are finish ground, the keyway cut, and the final axle tube housing assembly is washed, rust proofed, packaged, and shipped.
  • the conventional method of manufacturing a full-float axle tube suffers from a number of disadvantages.
  • this conventional manufacturing method requires an enormous amount of cycle time to cut, forge, extrude, weld, straighten, face, turn, and finish the axle tube housing blank, which increases the associated manufacturing costs and complexity.
  • a method of manufacturing an axle tube housing assembly quickly and conveniently without the need to first cut a tubular blank, process the sections separately, and later weld the sections back together.
  • a method of manufacturing an axle tube housing for a differential assembly which provides a number of unique advantages over conventional manufacturing methods.
  • the method of the present invention includes heating a localized area of a one-piece tubular blank.
  • a mandrel is inserted within the tubular blank and the localized area is then deformed to provide an increased wall thickness.
  • a compression force is applied to the localized area of the one-piece tubular blank using a forging die to form a spindle section, wherein the spindle section closely conforms to at least one of the forging die and the mandrel.
  • the remaining portion of the one-piece tubular blank is then cold reduced to form a carrier section.
  • FIGS. 1-17 are a series of plan views illustrating the sequential manufacturing steps of an axle tube housing assembly according to the principles of the prior art
  • FIG. 18 is a flowchart illustrating the sequential manufacturing steps of an axle tube housing assembly according to the principles of the prior art
  • FIGS. 19-26 are a series of plan views illustrating the sequential manufacturing steps of an axle tube housing according to the principles of the present invention.
  • FIG. 27 is a flowchart illustrating the sequential manufacturing steps of an axle tube housing assembly according to the principles of the present invention.
  • FIGS. 19-26 a preferred method of manufacturing an axle tube housing 100 (FIG. 26) is provided in accordance with the present invention.
  • the present invention provides a number of advantages over the previously recited conventional manufacturing method.
  • the present invention provides a method of manufacturing an axle tube housing 100 that eliminates a number of processing steps required in the conventional manufacturing method, such as the initial cutting of the tubular blank (step 50), the extruding of first section 10 (step 52), the warm forming of second section 12 (step 54), the cropping of the ends of first section 10 and/or second section 12 (step 56), the friction welding of first section 10 and second section 12 (step 58), the machining or shearing of the "ram's horn" 16 (step 60), the centering of the spindle end of first section 10 (step 70), the turning of the weld flange face (step 76), the turning of the outer diameter of first section 10 (step 78), and the drilling and deburring of the holes in the weld flange (step 82). Accordingly, it should be appreciated that the present invention maximizes the efficiency of the manufacturing process, thereby reducing the associated production costs thereof.
  • FIGS. 19-26 a series of plan views illustrating the sequential manufacturing steps of an axle tube housing 100 is provided according to the principles of the present invention.
  • the conventional forging process is simplified, which further reduces much of the need for extensive welding and machining.
  • the initial tubular blank is never cut into separate processing sections and, thus, does not require subsequent cropping, welding, or machining to join the sections back together.
  • a tubular blank 102 is first provided having a first end 104 and a second end 106.
  • Tubular blank 102 further defines an initial outer diameter (OD 0 ), an initial inner diameter (ID 0 ), and a generally uniform wall thickness (T 0 ).
  • first end 104 of tubular blank 102 is heated to facilitate the forming thereof.
  • first end 104 is heated in a predetermined localized area 108 using an induction- heating element 110.
  • Induction heating element 110 provides rapid, convenient, and discrete heating of predetermined localized area 108.
  • any heating system may be used that promotes the malleability of tubular blank 102, such as a warming oven, flame application, and the like.
  • first physical stop 112 is positioned and engaged in contact with first end 104 of tubular blank 102.
  • second physical stop 114 is positioned and engaged in contact with opposing second end 106 of tubular blank 102.
  • at least one of first physical stop 112 and second physical stop 114 is movable relative to the other to produce a clamping force upon tubular blank 102.
  • forming mandrel 116 is provided having a cross-sectional profile defined by the present design criteria.
  • forming mandrel 116 includes a first outer diameter (OD f mi), which is preferably sized to closely conform to a final desired inner diameter (ID fC ) of a carrier section 118 (FIG. 26) of axle tube housing 100.
  • Forming mandrel 116 further includes a second outer diameter (ODfm 2 ), which is preferably sized to closely conform to a final desired inner diameter (ID fS ) of a spindle section 120 (FIG.
  • a shoulder portion 122 extends between first outer diameter (ODfmi) and second outer diameter (ODfm 2 ).
  • forming mandrel 116 is inserted into locally heated tubular blank 102 such that shoulder portion 122 of forming mandrel 116 is generally adjacent localized area 108.
  • a clamping jaw 124 engages second end 106 of tubular blank 102 to retain tubular blank 102 in a position relative to forming mandrel 116 and second physical stop 114.
  • a forging die 126 is provided having an inner forging contour that defines a generally flat section 128 and a generally shaped section 130. Forging die 126 is generally conventional in operation and, thus, in the interest of brevity, its specific construction will not be described herein.
  • tubular blank 102 is initially positioned such that first physical stop 112 engages first end 104, second physical stop 114 engages second end 106, clamping jaw 124 engages second end 106, and forming mandrel 116 is inserted therein.
  • Generally flat section 128 of forging die 126 is then positioned generally adjacent localized area 108.
  • first physical stop 112 and/or second physical stop 114 are actuated to apply a compression force longitudinally along tubular blank 102. As can be seen in FIG.
  • this longitudinal compression force causes heated localized area 108 to deform inwardly into a void 132 defined by generally-flat section 128 of forging die 126, shoulder portion 122 of forming mandrel 116, and first physical stop 112.
  • This operation causes the wall thickness of tubular blank 102 to increase generally along localized area 108. This increased wall thickness provided the necessary material for later forming operations.
  • first physical stop 112 may now be removed and forming mandrel 116 may be partially retracted (to the right in FIG. 21 ).
  • Forging die 126 is then repositioned (to the left in FIG. 21 ) such that a portion of generally flat section 128 is adjacent first end 104. As seen in FIG.
  • forging die 126 is then actuated to separately or simultaneously move inwardly around forming mandrel 116 and to the right against shoulder portion 122.
  • This operation serves to initially reduce and shape first end 104 of tubular blank 102 to conform closely to forming mandrel 116 and generally shaped section 130 of forging die 126.
  • this technique further provides enormous control over the wall thickness of spindle section 120.
  • the relative position of forging die 126 and forming mandrel 116 defines areas where additional material (i.e. metal material) may be concentrated. This is particularly useful to provide improved strength capability in known failure locations (i.e. corners, bearing positions, etc.).
  • forging die 126 may now be retracted from tubular blank 102 and a second forging die 134, having similar construction to forging die 126, may now be used to form a final shape at spindle section 120 in a similar operation as previously described. It should be appreciated, however, that second forging die 134 may not be necessary in all applications.
  • forging die 134 is now positioned adjacent carrier section 118 of tubular blank 102. Accordingly, as seen in FIGS. 23-24, forging die 134 is then drawn along at least a portion of carrier section 118 to cold reduce the wall thickness (T) of at least a portion of carrier section 118 and, additionally, closely conform the inner diameter (ID) of carrier section 118 to the outer diameter (OD fm ⁇ ) of forming mandrel 116. Hence, following this operation (FIG.
  • wall thickness (T c ) of carrier section 118 is less than initial wall thickness (T 0 )
  • outer diameter (OD c ) of carrier section 118 is less than initial outer diameter (OD 0 )
  • inner diameter (ID C ) of carrier section 118 is less than initial inner diameter (ID 0 ).
  • such cold reduction of carrier section 118 is performed only along a portion of carrier section 118, thereby leaving a section 136 having initial (enlarged) wall thickness (T 0 ).
  • the outer diameter (OD- I36 ) of section 136 can be reduced to be consistent with the adjacent cold- reduced section of carrier section 118 (OD c ). That is, forming mandrel 116 may be retracted (moved to the right in FIG. 25) such that forming mandrel 116 no longer engages an inner diameter (ID ⁇ 36 ) of section 116.
  • Forging die 134 is then drawn along section 136 to cold reduce the outer diameter thereof, without dramatically affecting the wall thickness (T ⁇ 3 ⁇ ) of section 136.
  • the resultant effect of this process is to provide locations along carrier section 118 where the wall thickness may be increased or decreased in accordance with the necessary structural loading requirements. Therefore, areas that contribute less to structural loading capacity may be thinner, thereby reducing the total weight of the assembly. Conversely, areas that contribute greater to structural loading capacity may be thicker, thereby improving the overall structural integrity. It should be understood that the thickness of carrier section 118 may be varied along its length as necessary to maximize integrity while minimizing weight and cost.
  • axle tube housing 100 is now forged from a single unitary tubular blank.
  • the final forged axle tube housing 100 thus includes spindle section 120 having a cross-sectional profile that varies in wall thickness, a first portion of carrier section 118 having a generally uniform wall thickness, and a second portion of carrier section 118 having a generally uniform wall thickness greater than the first portion.
  • axle tube housing 100 may include a plurality of bracket welding steps, which is dependent upon the specific application and vehicle design.
  • One important process step reduction feature is to provide a flat steel plate with precision, fine-blanked, brake backing plate 180 with mounting holes as a substitute for the conventionally-formed, unfinished, no-holed, weld flange bracket 18.
  • Plate 180 is pressed on to axle tube housing 100 at a predetermined position relative to an established datum (step 620). Plate 180 is subsequently fusion welded in a final position to axle tube housing 100, without the need for additional centering or machining.
  • axle tube housing 100 may conveniently be mounted to axle tube housing 100 as a finished member, without the need for difficult and time consuming centering and drilling.
  • the remaining axle tube brackets such as a spring seat and a shock mount, may then be welded to axle tube housing 100 in a predetermined position (step 640).
  • axle tube housing 100 may then be straightened as necessary (step 660).
  • axle tube housing 100 may then be machined to provide the necessary finishing steps in the manufacturing process.
  • spindle section 120 is faced (step 680), although due to the one-piece construction of the present invention, spindle section 120 need not be centered as required by conventional manufacturing processes (the datum line for all subsequent spindle turning operations may be defined by the line passing through the center line of the rear end of axle tube housing 100 and extending through the center of the tube engagement hole in the fine blanked weld flange plate 180); second end 106 of carrier section 118 is faced and centered (step 720); spindle section 120 of axle tube housing 100 is turned and/or roll threaded (steps 740 and 800); and finally the bearing and seal surfaces of axle tube housing 100 are finish ground, the keyway cut, and the final axle tube housing assembly is washed, rust proofed, packaged, and shipped (steps 840 and 860).
  • the manufacturing method of the present invention provides a number of advantages over conventional manufacturing methods in that the present invention improves the structural integrity of the axle tube housing by using a single, unitary member; eliminates the need for cutting, processing, and welding of multiple sections; reduces the need for complex machinery; and finally minimizes cycle time and associated costs. Furthermore, on a granular level, it should be understood that the method of manufacturing according to the present invention provides an axle tube housing that employs a substantially homogenous grain structure throughout its length by virtue of its unitary construction, thereby providing a more consistent and predictable member.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Motor Power Transmission Devices (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'une trompette tubulaire pour un ensemble différentiel. Selon ce procédé, on chauffe une zone localisée (108) d'une ébauche tubulaire monobloc (102). On introduit un mandrin (116) dans l'ébauche tubulaire, ce qui fait que la zone localisée (108) se déforme pour donner naissance à une surépaisseur de la paroi. En exerçant sur la zone localisée de l'ébauche tubulaire monobloc une force de compression au moyen d'un outil à forger (126), on donne sa forme au segment de la fusée d'essieu, laquelle épouse étroitement la forme de l'outil à forger considéré (126) et du mandrin (116). Le restant de l'ébauche tubulaire monobloc est alors réduit à froid pour former un segment en palier.
EP03754509A 2002-09-16 2003-09-11 Ensemble trompette tubulaire monobloc Withdrawn EP1539396A1 (fr)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US41147302P 2002-09-16 2002-09-16
US411473P 2002-09-16
US10/645,943 US20040060385A1 (en) 2002-09-16 2003-08-22 One-piece axle tube housing assembly
US645943 2003-08-22
PCT/US2003/028607 WO2004024366A1 (fr) 2002-09-16 2003-09-11 Ensemble trompette tubulaire monobloc

Publications (1)

Publication Number Publication Date
EP1539396A1 true EP1539396A1 (fr) 2005-06-15

Family

ID=32033548

Family Applications (1)

Application Number Title Priority Date Filing Date
EP03754509A Withdrawn EP1539396A1 (fr) 2002-09-16 2003-09-11 Ensemble trompette tubulaire monobloc

Country Status (5)

Country Link
EP (1) EP1539396A1 (fr)
JP (1) JP2006500218A (fr)
KR (1) KR20050042816A (fr)
AU (1) AU2003272332A1 (fr)
BR (1) BR0314217A (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5880037B2 (ja) * 2011-12-28 2016-03-08 日本精工株式会社 段付金属部材の製造方法
US9982706B2 (en) 2015-07-31 2018-05-29 Hyundai Motor Company Method of manufacturing light rotor shaft for eco-friendly vehicles

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2004024366A1 *

Also Published As

Publication number Publication date
JP2006500218A (ja) 2006-01-05
BR0314217A (pt) 2005-07-12
AU2003272332A1 (en) 2004-04-30
KR20050042816A (ko) 2005-05-10

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