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WO2004026630A2 - Method of making automotive parts having spline - Google Patents

Method of making automotive parts having spline Download PDF

Info

Publication number
WO2004026630A2
WO2004026630A2 PCT/US2003/029439 US0329439W WO2004026630A2 WO 2004026630 A2 WO2004026630 A2 WO 2004026630A2 US 0329439 W US0329439 W US 0329439W WO 2004026630 A2 WO2004026630 A2 WO 2004026630A2
Authority
WO
WIPO (PCT)
Prior art keywords
spline
tool
bore
automotive part
automotive
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.)
Ceased
Application number
PCT/US2003/029439
Other languages
French (fr)
Other versions
WO2004026630A9 (en
WO2004026630A3 (en
Inventor
Markus Knoerr
Erhard Ambuhl
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.)
Metaldyne Co LLC
Original Assignee
Metaldyne Co LLC
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
Application filed by Metaldyne Co LLC filed Critical Metaldyne Co LLC
Priority to AU2003278837A priority Critical patent/AU2003278837A1/en
Publication of WO2004026630A2 publication Critical patent/WO2004026630A2/en
Publication of WO2004026630A9 publication Critical patent/WO2004026630A9/en
Publication of WO2004026630A3 publication Critical patent/WO2004026630A3/en
Anticipated expiration legal-status Critical
Ceased 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/12—Forming profiles on internal or external surfaces
    • 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

Definitions

  • the present invention relates to the field of automotive parts. Particularly, the present invention is directed to a method of making automotive parts having an interior spline through the use of a metal forming process.
  • parts having splines are particularly useful in creating interlocking articles or other useful features in automotive parts.
  • automotive parts having one or more splines needed to be manufactured in a series of main steps — most typically, forging, turning, pressing, refining and broaching.
  • forging step a rod member is cut, heated, shaped and trimmed to prepare a basic form of the spline part.
  • broaching step splines are then cut into the interior of the
  • spline broach Page l part through the use of a spline broach.
  • U.S. Patent 2,726,435 discloses a reciprocating broach, used to make particularized shapes on the interior of a bore, wherein the broach possesses multiple axially aligned cutting teeth.
  • This spline broach along with many others known in the art, is problematic for automotive parts requiring a durable, high-strength spline because splines formed by such broach are often defective at a rate that is unacceptable to the automotive industry. More generally, spline broaches are relatively unsuitable for small-sized splines.
  • the cutting action of the broach itself possess substantial hazards to the safety of those making the splines as well as to the quality of the part being broached (for example, in the event that the cutting broach fails or the point of contact for the reciprocating action is inconsistent during the process).
  • the present invention is directed to a method of manufacturing an automotive part including a spline.
  • the method includes forging an automotive part.
  • the automotive part includes a bore.
  • the method further includes machining the part and the bore.
  • the method further includes pressing a spline tool into the machined bore.
  • the spline tool includes one or more spline grooves.
  • the width or diameter of the tool is equal to or greater than the width or diameter of the bore.
  • the pressing of the tool into the bore displaces the metal along an interior axis of the bore, thereby creating one or more splines (depending upon the shape of the tool).
  • the automotive part is formed from a high strength metal, such as a steel alloy with relatively high carbon content, preferably at least 0.5-1.0%.
  • FIGURE 1 shows a cross-section of an automotive part 10 and a spline tool 14 where the tool 14 is being pushed in to the bore 12 of the part 10.
  • FIGURE 2 shows a perspective view of a preferred embodiment wheel spindle 20.
  • FIGURE 3 shows a perspective view of a terminal end of a spline tool 14 having two spline grooves 18.
  • the present invention is directed to a method for manufacturing an automotive part having a spline.
  • the method includes forging an automotive part, where the automotive part defines a bore.
  • the method further includes machining the automotive part and bore to a desired shape.
  • the method also includes pressing a tool including at least one spline groove into the bore with sufficient force so that the tool forms a spline on the inner portion of the part in the bore.
  • FIGURE 1 shows an automotive part 10 defining a bore 12.
  • a spline tool 14 is pushed towards the automotive part 10.
  • the bottom 16 of the spline tool 14 that first contacts the automotive part 10 has a diameter equal to or greater than the width or diameter of the bore.
  • the spline tool 14 contacts the inner edge of the automotive part 10 that defines the bore 12.
  • the spline tool 14 includes one or more spline grooves 18.
  • the spline tool 14 includes two spline grooves 18.
  • the spline grooves 18 are generally recessed so that when the tool 14 machines the bore 12 of the part 10, a spline is formed on the inner portion of the part 10 defining the bore.
  • the tool 14 forms the metal of the part 10 in such a manner that carves away or shaves out a portion of the material forming the inner portion of automotive part 10 and defining the bore 12.
  • the metal forming process accomplished by the tool 14 occurs in a single downward movement relative to the part 10, thereby eliminating any need to have the tool 14 reciprocate during the metal forming process.
  • Splines are formed on the inner portion of the part 10 defining the bore 12 in a pattern which mirrors the spline grooves 18 of tool 14.
  • the spline grooves 18 are preferably formed at a terminal end of the tool 14.
  • the number of grooves may vary according to the type of automotive part 10 being manufactured. However, as best illustrated in FIGURES 1 and 3, it is anticipated that a tool 14 having two grooves 18 which commence at a terminal end of the tool 14 and run parallel to one another along only an axial portion of the tool 14 (rather than the entire axial length of the tool 14) will be a preferred embodiment.
  • any automotive part that requires the machining of a spline is contemplated in the present invention.
  • the automotive part formed with the present method is a wheel spindle, although of course other automotive parts are contemplated.
  • FIGURE 2 shows the preferred wheel spindle 20 that defines a bore 22 along its longitudinal axis.
  • the automotive part formed with the present method defines an aperture or bore.
  • the spline is formed on the automotive part in the bore.
  • the bore is generally cylindrical although other shapes are contemplated.
  • the automotive part is formed from a steel alloy material.
  • the material forming the part includes a relatively high amount of carbon in the range of from about 0.5% to about 1.0% by weight.
  • carbon in amount greater than 2% by weight should be avoided because such a high amount of carbon forms an iron exhibiting undesirably high brittleness properties.
  • the spline tool is generally cylindrically shaped, although other shapes are contemplated.
  • the shape of the spline tool will be the same as the shape of the bore.
  • the tool includes one or more spline grooves.
  • FIGURE 3 shows the bottom of a spline tool 14 having two spline grooves 18; however, the spline grooves can be of any shape depending on the desired shape of the final spline formed in the automotive part.
  • the inner width or diameter of the tool 14 is preferably greater than the width or diameter of the bore, whereas the outer diameter of the tool 14 must allow for appropriate contact between the tool 14 and the part 10 during the pressing, or metal forming, part of the process.
  • the inner diameter is defined by the narrowest width of the tool (for example, as shown in FIGURE 3, from one edge of the spline groove 18 to the opposite edge along the bottom end 16), while the outer diameter represents the thickest width of the tool 14.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

The present invention is directed to a method of making an automotive part having a spline. Preferably, the automotive part is a high strength automotive part having a relatively high carbon content. The method includes pressing a spline tool having one or more spline grooves into a bore defined by the automotive part so that one or more splines are formed through the displacement of material on the interior of the bore.

Description

Title
METHOD OF MAKING AUTOMOTIVE PARTS HAVING SPLINE
Prior Applications
The application claims priority from provisional application serial number 60/412,654, filed September 20, 2002.
Field of the Invention
[0001] The present invention relates to the field of automotive parts. Particularly, the present invention is directed to a method of making automotive parts having an interior spline through the use of a metal forming process.
Background of the Invention
[0002] In the automotive field, parts having splines are particularly useful in creating interlocking articles or other useful features in automotive parts. Previously, automotive parts having one or more splines needed to be manufactured in a series of main steps — most typically, forging, turning, pressing, refining and broaching. In the forging step, a rod member is cut, heated, shaped and trimmed to prepare a basic form of the spline part. In the final broaching step, splines are then cut into the interior of the
Page l part through the use of a spline broach. For example, U.S. Patent 2,726,435 discloses a reciprocating broach, used to make particularized shapes on the interior of a bore, wherein the broach possesses multiple axially aligned cutting teeth. This spline broach, along with many others known in the art, is problematic for automotive parts requiring a durable, high-strength spline because splines formed by such broach are often defective at a rate that is unacceptable to the automotive industry. More generally, spline broaches are relatively unsuitable for small-sized splines. Lastly, the cutting action of the broach itself possess substantial hazards to the safety of those making the splines as well as to the quality of the part being broached (for example, in the event that the cutting broach fails or the point of contact for the reciprocating action is inconsistent during the process).
[0003] Thus, it would be advantageous to form high-strength splines in automotive parts in a manner that displaces, rather than cuts, the metal — thereby resulting in superior quality splines in comparison to previously known spline-cutting methods.
Summary of the Invention
[0004] The present invention is directed to a method of manufacturing an automotive part including a spline. The method includes forging an automotive part. Preferably, the automotive part includes a bore. The method further includes machining the part and the bore. The method further includes pressing a spline tool into the machined bore. The spline tool includes one or more spline grooves. Preferably, the width or diameter of the tool is equal to or greater than the width or diameter of the bore. The pressing of the tool into the bore displaces the metal along an interior axis of the bore, thereby creating one or more splines (depending upon the shape of the tool). Preferably, the automotive part is formed from a high strength metal, such as a steel alloy with relatively high carbon content, preferably at least 0.5-1.0%.
[0005] Still other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description.
Brief Description of the Drawings
[0006] The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment and method of which will be described in detail in this specification and illustrated in the accompanying drawings that form a part hereof, and wherein:
[0007] FIGURE 1 shows a cross-section of an automotive part 10 and a spline tool 14 where the tool 14 is being pushed in to the bore 12 of the part 10. [0008] FIGURE 2 shows a perspective view of a preferred embodiment wheel spindle 20.
[0009] FIGURE 3 shows a perspective view of a terminal end of a spline tool 14 having two spline grooves 18.
Detailed Description of the Preferred Embodiment
[00010] The present invention is directed to a method for manufacturing an automotive part having a spline. The method includes forging an automotive part, where the automotive part defines a bore. The method further includes machining the automotive part and bore to a desired shape. The method also includes pressing a tool including at least one spline groove into the bore with sufficient force so that the tool forms a spline on the inner portion of the part in the bore.
[00011] FIGURE 1 shows an automotive part 10 defining a bore 12. A spline tool 14 is pushed towards the automotive part 10. The bottom 16 of the spline tool 14 that first contacts the automotive part 10 has a diameter equal to or greater than the width or diameter of the bore. Thus, the bottom 16 of the spline tool 14 contacts the inner edge of the automotive part 10 that defines the bore 12. [00012] The spline tool 14 includes one or more spline grooves 18. In the spline' tool shown in FIGURE 1, the spline tool 14 includes two spline grooves 18. The spline grooves 18 are generally recessed so that when the tool 14 machines the bore 12 of the part 10, a spline is formed on the inner portion of the part 10 defining the bore.
[00013] In operation, when the spline tool 14 is pressed into the bore 12 of the automotive part 10, the tool 14 forms the metal of the part 10 in such a manner that carves away or shaves out a portion of the material forming the inner portion of automotive part 10 and defining the bore 12. Notably, the metal forming process accomplished by the tool 14 occurs in a single downward movement relative to the part 10, thereby eliminating any need to have the tool 14 reciprocate during the metal forming process. Splines are formed on the inner portion of the part 10 defining the bore 12 in a pattern which mirrors the spline grooves 18 of tool 14.
[00014] The spline grooves 18 are preferably formed at a terminal end of the tool 14. The number of grooves may vary according to the type of automotive part 10 being manufactured. However, as best illustrated in FIGURES 1 and 3, it is anticipated that a tool 14 having two grooves 18 which commence at a terminal end of the tool 14 and run parallel to one another along only an axial portion of the tool 14 (rather than the entire axial length of the tool 14) will be a preferred embodiment.
[00015] Any automotive part that requires the machining of a spline is contemplated in the present invention. Preferably, the automotive part formed with the present method is a wheel spindle, although of course other automotive parts are contemplated. FIGURE 2 shows the preferred wheel spindle 20 that defines a bore 22 along its longitudinal axis. Preferably, the automotive part formed with the present method defines an aperture or bore. The spline is formed on the automotive part in the bore. The bore is generally cylindrical although other shapes are contemplated.
[00016] The automotive part is formed from a steel alloy material. Preferably, the material forming the part includes a relatively high amount of carbon in the range of from about 0.5% to about 1.0% by weight. Generally, carbon in amount greater than 2% by weight should be avoided because such a high amount of carbon forms an iron exhibiting undesirably high brittleness properties.
[00017] The spline tool is generally cylindrically shaped, although other shapes are contemplated. Preferably, the shape of the spline tool will be the same as the shape of the bore. The tool includes one or more spline grooves. FIGURE 3 shows the bottom of a spline tool 14 having two spline grooves 18; however, the spline grooves can be of any shape depending on the desired shape of the final spline formed in the automotive part. The inner width or diameter of the tool 14 is preferably greater than the width or diameter of the bore, whereas the outer diameter of the tool 14 must allow for appropriate contact between the tool 14 and the part 10 during the pressing, or metal forming, part of the process. The inner diameter is defined by the narrowest width of the tool (for example, as shown in FIGURE 3, from one edge of the spline groove 18 to the opposite edge along the bottom end 16), while the outer diameter represents the thickest width of the tool 14. [00018] The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims

ClaimsHaving thus described the invention, it is claimed:
1. A method of manufacturing an automotive part having a spline comprising: forging an automotive part, said automotive part including a bore; pressing a tool having at least one spline-generating groove into said bore to form an automotive part having a spline.
2. A method according to claim 1 , wherein the part is formed from a high strength carbon steel alloy.
3. A method according to claim 2, wherein the high strength carbon steel alloy comprises at least 0.5% carbon.
4. A method according to claim 1 , wherein the tool has an axial length and two spline-generating grooves, said grooves commencing at a terminal end of the tool and running along a portion of the axial length of the tool that is less than the entire axial length of the tool.
PCT/US2003/029439 2002-09-20 2003-09-22 Method of making automotive parts having spline Ceased WO2004026630A2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003278837A AU2003278837A1 (en) 2002-09-20 2003-09-22 Method of making automotive parts having spline

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US41265402P 2002-09-20 2002-09-20
US60/412,654 2002-09-20

Publications (3)

Publication Number Publication Date
WO2004026630A2 true WO2004026630A2 (en) 2004-04-01
WO2004026630A9 WO2004026630A9 (en) 2004-05-27
WO2004026630A3 WO2004026630A3 (en) 2004-12-29

Family

ID=32030922

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2003/029439 Ceased WO2004026630A2 (en) 2002-09-20 2003-09-22 Method of making automotive parts having spline

Country Status (3)

Country Link
US (1) US20040134252A1 (en)
AU (1) AU2003278837A1 (en)
WO (1) WO2004026630A2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140239707A1 (en) * 2007-03-22 2014-08-28 Ntn Corporation Bearing device for a wheel

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1410093A (en) * 1919-03-22 1922-03-21 Valley Forging Company Method of forming metal-hubbed articles
US2165977A (en) * 1936-05-26 1939-07-11 Westinghouse Air Brake Co Broaching device
US2562668A (en) * 1948-02-07 1951-07-31 Nellie M Gottschalt Broach
US2726435A (en) * 1954-08-23 1955-12-13 Verl R Farnsworth Broaching tool
US3699636A (en) * 1971-02-17 1972-10-24 Whittaker Corp Metal bonding process
US4543813A (en) * 1983-09-19 1985-10-01 Trw Cam Gears Limited Method of making valve sleeves
JP3135553B2 (en) * 1990-09-01 2001-02-19 日本電産株式会社 Spindle motor
DE19602907A1 (en) * 1996-01-27 1997-07-31 Bosch Gmbh Robert Fastening arrangement of a fuel line on a nozzle
US6408669B1 (en) * 2000-11-15 2002-06-25 Delphi Technologies, Inc. Method and apparatus for wheel spindles and the like with improved LRO

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140239707A1 (en) * 2007-03-22 2014-08-28 Ntn Corporation Bearing device for a wheel
US9039286B2 (en) * 2007-03-22 2015-05-26 Ntn Corporation Bearing device for a wheel
US9321309B2 (en) 2007-03-22 2016-04-26 Ntn Corporation Manufacturing method for a bearing device for a wheel
US9511629B2 (en) * 2007-03-22 2016-12-06 Ntn Corporation Bearing device for a wheel

Also Published As

Publication number Publication date
AU2003278837A8 (en) 2004-04-08
AU2003278837A1 (en) 2004-04-08
WO2004026630A9 (en) 2004-05-27
US20040134252A1 (en) 2004-07-15
WO2004026630A3 (en) 2004-12-29

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