Method for forming two piece axle shaft

• US 6,698,078 B2
• Filed: 01/08/2003
• Issued: 03/02/2004
• Est. Priority Date: 06/21/2001
• Status: Expired due to Fees

• Current Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Original Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Inventors: Prucher, Bryan Paul
• Primary Examiner(s): Hong, John C.
• Application Number:
  US10/338,453
• Publication Number:
  US 20030093888A1
• Time in Patent Office: 419 Days
• Field of Search: 294/28, 295/25, 295/251.4, 298/93, 298/931, 298/932, 298/933--89, 295/57, 301/124.1, 301/126, 464/179, 464/182, 475/230
• US Class Current: 29/428
• CPC Class Codes: B60K 17/165 provided between independent half axles B60K17/18, B60K17/20 take precedence
• CPC Class Codes: B60K 17/22 characterised by arrangement, location, or type of main drive shafting, e.g. cardan shaft
• CPC Class Codes: F16D 1/068 involving gluing, welding or the like
• CPC Class Codes: F16D 2001/103 the torque is transmitted via splined connections
• CPC Class Codes: F16H 2048/082 characterised by the arrangement of output shafts
• CPC Class Codes: F16H 2048/405 characterised by features of the bearing of the rotating case
• CPC Class Codes: F16H 2048/423 characterised by bearing arrangement
• CPC Class Codes: F16H 48/08 comprising bevel gears
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/49995 Shaping one-piece blank by removing material

Abstract

An axle shaft for a differential assembly. The axle shaft includes a shaft structure and a flange structure. The shaft structure has a coupling portion with an engagement surface. The flange structure is formed in a fine blanking operation and has a mounting aperture with a contact surface. The mounting aperture is sized to receive the coupling portion such that the engagement surface and the contact surface are engaged to one another so as to facilitate transmission of rotary power therebetween. The shaft structure and the flange structure are fixedly secured to one another to facilitate the transmission of rotary power therebetween.

Claims

1. A method for forming an axle shaft, comprising:

forming a flange structure, the flange structure including a mounting aperture and a contact surface that are formed through fine blanking;

providing a shaft structure having a coupling portion with an engagement surface; and

coupling the shaft structure and the flange structure such that the engagement surface is engaged to the contact surface to transmit rotary power therebetween.

2. The method of claim 1, wherein the shaft structure is formed from a first material and the flange structure is formed from a second material that is different from the first material.

3. The method of claim 1, wherein the shaft structure is formed from a generally tubular material.

4. The method of claim 3, wherein the tubular material is welded tubing.

5. The method of claim 3, wherein at least a portion of the shaft structure is formed in a rotary swaging operation.

6. The method of claim 1, wherein the engagement surface has a non-circular shape that is configured to matingly engage the contact surface.

7. The method of claim 6, wherein one of the engagement and contact surfaces includes a plurality of spline teeth for engaging a plurality of spline apertures formed in the other one of the engagement and contact surfaces.

8. The method of claim 7, wherein the plurality of spline teeth are formed onto the shaft structure in a roll forming operation.

9. The method of claim 1, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least one laser weld.

10. The method of claim 1, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least one projection weld for fixedly coupling the shaft structure and the flange structure.

11. The method of claim 1, wherein the shaft structure and the flange structure are coupled by a coupling means that includes an interference fit between the engagement surface and the contact surface.

12. The method of claim 1, wherein the shaft structure includes an input spline that is adapted to matingly engage a spline aperture formed in a side gear of the differential assembly.

13. The method of claim 1, wherein the coupling portion further includes a head portion that is at least partially disposed within a secondary mounting aperture formed into the flange structure.

14. The method of claim 13, wherein a portion of the head portion has a diameter that is larger than a diameter of the mounting aperture.

15. The method of claim 13, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least one laser weld for fixedly coupling the head portion to the flange structure.

16. The method of claim 13, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least on projection weld for fixedly coupling the head portion and the flange structure.

17. The method of claim 13, wherein the shaft structure and the flange structure are coupled by a coupling means that includes an interference fit between the head portion and the secondary mounting aperture.

18. The method of claim 13, wherein the head portion includes a secondary engagement surface and the secondary mounting aperture has a secondary contact surface, the secondary engagement surface having a non-circular shape that is configured to matingly engage the secondary contact surface.

19. The method of claim 18, wherein one of the secondary engagement and secondary contact surfaces includes a plurality of spline teeth for engaging a plurality of spline apertures formed in the other one of the secondary engagement and secondary contact surfaces.

20. The method of claim 19, wherein the plurality of spline teeth are formed onto the head portion in a roll forming operation.

21. The method of claim 1, wherein the flange structure is formed from a sheet material that has been processed in a rolling operation.

22. The method of claim 1, wherein the shaft structure further comprises a bearing surface that is adapted to engage in a press-fit manner a race of a bearing.

23. A method for forming an axle shaft, comprising:

providing a shaft structure having a coupling portion that defines an engagement surface and a head portion with an abutting flange;

forming a flange structure in a fine blanking operation such that the flange structure includes an elongated center hub, a mounting aperture and a secondary mounting aperture, the mounting aperture extending through the center hub, the secondary mounting aperture terminating at an abutting face on a first side of the center hub, the mounting aperture defining a contact surface; and

coupling the flange structure and the shaft structure such that the shaft structure is partially received through the mounting aperture so that the contact surface engages the engagement surface and the head portion is at least partially received into the secondary mounting aperture such that the abutting flange confronts the abutting face.

24. The method of claim 23, wherein the flange structure is formed from a flat stock or sheet material.

25. The method of claim 24, wherein the flat stock or sheet material has been rolled to elongate its grain structure in a predetermined direction.

26. The method of claim 23, wherein the shaft structure is formed from a first material and the flange structure is formed from a second material that is different from the first material.

27. The method of claim 23, wherein the shaft structure is formed from a generally tubular material.

28. The method of claim 27, wherein the tubular material is welded tubing.

29. The method of claim 27, wherein at least a portion of the shaft structure is formed in a rotary swaging operation.

30. The method of claim 23, wherein the engagement surface has a non-circular shape that is configured to matingly engage the contact surface.

31. The method of claim 30, wherein one of the engagement and contact surfaces includes a plurality of spline teeth for engaging a plurality of spline apertures formed in the other one of the engagement and contact surfaces.

32. The method of claim 31, wherein the plurality of spline teeth are formed onto the shaft structure in a roll forming operation.

33. The method of claim 23, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least one laser weld.

34. The method of claim 23, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least one projection weld for fixedly coupling the shaft structure and the flange structure.

35. The method of claim 23, wherein the shaft structure and the flange structure are coupled by a coupling means that includes an interference fit between the engagement surface and the contact surface.

36. The method of claim 23, wherein the shaft structure includes an input spline that is adapted to matingly engage a spline aperture formed in a side gear of the differential assembly.

37. The method of claim 23, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least one laser weld for fixedly coupling the head portion to the flange structure.

38. The method of claim 23, wherein the shaft structure and the flange structure are coupled by a coupling means that includes at least on projection weld for fixedly coupling the head portion and the flange structure.

39. The method of claim 23, wherein the shaft structure and the flange structure are coupled by a coupling means that includes an interference fit between the head portion and the secondary mounting aperture.

40. The method of claim 23, wherein the shaft includes a secondary contact surface and the secondary mounting aperture defines a secondary engagement surface which engages the secondary contact surface, wherein the secondary contact surface is defined by a first periodic wave, wherein the secondary engagement surface is defined by a second periodic wave similar to the first periodic wave.

41. The method of claim 40, wherein the first periodic wave is formed in a roll forming operation.

42. The method of claim 23, wherein the shaft structure further comprises a bearing surface that is adapted to engage in a press-fit manner a race of a bearing.