Method of constructing a one-piece aluminum differential housing

• US 3,905,089 A
• Filed: 02/22/1974
• Issued: 09/16/1975
• Est. Priority Date: 02/22/1974
• Status: Expired due to Term

• Current Assignee: Carl D. Osenbaugh, Ronald E. Bollet
• Original Assignee: Carl D. Osenbaugh, Ronald E. Bollet
• Inventors: Osenbaugh, Carl D., Bollet, Ronald E.
• Primary Examiner(s): Scott, Samuel
• Assistant Examiner(s): Reep, John
• Application Number:
  US05/445,009
• Time in Patent Office: 571 Days
• Field of Search: 74/607,710,713 301/124H 29/527.6,434,196.2 164/111 180/88
• US Class Current: 29/434
• CPC Class Codes: B60K 17/16 of differential gearing
• CPC Class Codes: F16H 2057/02043 for vehicle transmissions
• CPC Class Codes: F16H 2057/02052 Axle units; Transfer casings for four wheel drive
• CPC Class Codes: F16H 2057/02091 Measures for reducing weight of gearbox by using particular materials F16H57/032
• CPC Class Codes: F16H 48/08 comprising bevel gears
• CPC Class Codes: F16H 57/023 Mounting or installation of gears or shafts in the gearboxes, e.g. methods or means for assembly
• CPC Class Codes: F16H 57/037 Gearboxes for accommodating differential gearings rotating cases for differential gearings F16H48/40
• CPC Class Codes: Y10T 29/4984 Retaining clearance for motion between assembled parts
• CPC Class Codes: Y10T 29/49989 Followed by cutting or removing material
• CPC Class Codes: Y10T 74/2188 Axle and torque tubes

Abstract

An axle including a unitized carrier housing and a method of constructing the same are provided. The carrier housing comprises an one-piece casting with a cover plate. Sleeves are cast integrally with the housing and provide a means of attachment and alignment for the tubes within which are carried the axle shafts. Preferably the sleeves are knurled or otherwise provided with an irregular surface to provide a secure attachment to the housing. The sleeves also provide access to the interior of the differential housing for machining the bearing seats within the housing. This construction and method of assembly is most advantageous in providing unitized carrier housings of cast aluminum and like materials which are not readily amenable to being welded, subsequent to machining, to the axle tubes.

Claims

1. A method of constructing an axle including a differential said method comprising:

a. providing a pair of axially aligned sleeves;

b. casting an one-piece differential housing of aluminum or the like about said sleeves;

c. inserting a cutting tool through said sleeves and machining bearing seats in said housing adjacent to said sleeves;

d. placing a tube in mating and axially overlapping relationship with each of said sleeves and securing said tubes of the associated one of said sleeves and installing differential gearing within said housing, said gearing including bearings mating with the seats machined in step c; and

e. inserting axle shafts through said tubes and sleeves and into driving engagement with said differential gearing.

2. A method of constructing an axle including a differential said method comprising:

a. providing a sleeve and a first tube in axial alignment b. casting an one-piece differential housing of aluminum or the like about said sleeve and tube;

c. inserting a cutting tool through said sleeve and machining bearing seats in said housing adjacent to said sleeve and said tube;

d. placing a second tube in mating and axially overlapping relationship with said sleeve and securing said tube to said sleeve and installing differential gearing within said housing, said gearing including bearings mating with the seats machined in step c; and

e. inserting axle shafts through said tubes and sleeve and into driving engagement with said differential gearing.