Information
-
Patent Grant
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6701763
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Patent Number
6,701,763
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Date Filed
Monday, August 27, 200122 years ago
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Date Issued
Tuesday, March 9, 200420 years ago
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Inventors
-
Original Assignees
-
Examiners
Agents
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CPC
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US Classifications
Field of Search
US
- 301 1241
- 301 125
- 301 126
- 301 131
- 029 8972
- 029 4211
- 072 37022
- 072 37023
- 072 37024
- 072 37025
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International Classifications
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Abstract
An axle assembly is provided that includes a tubular member having an outer wall and an interior cavity. The other wall includes a first interlocking feature. An axle component mounting member, such as a bearing shoulder sleeve and/or a brake flange, is arranged on a portion of the outer wall. The mounting member includes a second interlocking feature coacting with the first interlocking feature to affix the mounting member and tubular member to one anther. The axle assembly may be formed by arranging the axle mounting member into a die assembly. A tubular member may be arranged in the die assembly within an opening in the mounting member. A hydroforming process may be employed to pressurize a cavity within the tubular member. A portion of the tubular member is deformed into engagement with the mounting member to affix the mounting member to the tubular member.
Description
BACKGROUND OF THE INVENTION
This invention relates to an axle assembly, and more particularly, the invention relates to a hydroformed axle with a bearing shoulder and brake flange that are secured thereto preferably without the use of welds.
Many prior art axle assemblies, such as for use in trucks or trailers, are constructed from tubes or solid members that are straight or bent to a desired shape. Numerous components are typically secured to the axle, typically by welding the axle component to the axle. For example, the brake assembly is supported on the axle by a brake flange, which is welded to the axle. Welding components to the axle requires that a consumable welding material be deposited on the brake component axle in a relatively precise manner. As a result, the welding process may be expensive and difficult to control.
The wheels are supported on the ends of the axle on bearing assemblies. Bearing races are pressed onto the axle to abut a shoulder, which may be machined onto the axle, to locate the bearings axially. Machining can be a relatively expensive process therefore, what is needed is an axle assembly on which a bearing shoulder may be provided and to which a brake flange may be secured to without the use of expensive machining or welding.
SUMMARY OF THE INVENTION AND ADVANTAGES
The present invention provides an axle assembly including a tubular member having an outer wall and an interior cavity. The other wall includes a first interlocking feature. An axle component mounting member, such as a bearing shoulder sleeve and/or a brake flange, is arranged on a portion of the outer wall. The mounting member includes a second interlocking feature coacting with the first interlocking feature to affix the mounting member and tubular member to one anther. The axle assembly may be formed by arranging the axle mounting member into a die assembly. A tubular member may be arranged in the die assembly within an opening in the mounting member. A hydroforming process may be employed to pressurize a cavity within the tubular member. A portion of the tubular member is deformed into engagement with the mounting member to affix the mounting member to the tubular member.
Accordingly, the above invention provides an axle assembly on which a bearing shoulder may be provided and to which a brake flange may be secured to without the use of expensive machining or welding.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1
is a cross sectional view of a tubular member and axle component mounting member within a die assembly forming the axle assembly of the present invention;
FIG. 2
is an enlarged view of the axle assembly of the present invention subsequent to forming;
FIG. 3
is a side elevational view of a bearing shoulder sleeve and brake flange secured to the tubular member by the present invention axle forming process;
FIG. 4
is a cross-sectional view of the bearing shoulder sleeve taken along lines
4
—
4
of
FIG. 3
;
FIG. 5A
is a partial cross-sectional view of one embodiment of the interlocking features taken along line
5
—
5
of
FIG. 3
; and
FIG. 5B
is a partial cross-sectional view of another embodiment of the interlocking features taken along line
5
—
5
of FIG.
3
.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The die assembly
10
is shown in
FIGS. 1 and 2
and includes first
12
and second
14
die portions. Together the die portions
12
and
14
provide a forming surface
15
that defines the shape of the axle assembly to be formed. The die portions
12
and
14
include mounting member receptacles
18
and
20
within the forming cavity
16
of the die assembly
10
. A bearing shoulder sleeve
22
may be arranged in one of the receptacles
18
, and a brake flange
24
may be arranged in the other receptacle
20
. The bearing shoulder sleeve
22
provides a shoulder against which bearing assemblies may be installed. The brake flange
24
provides a mount to which a brake assembly for the wheel may be secured.
The bearing shoulder sleeve
22
and brake flange
24
respectively include openings
23
and
25
. A tubular member
26
is inserted into the forming cavity
16
and is arranged within the openings
23
and
25
. The tubular member
26
includes an outer wall
28
and an interior cavity
30
. Utilizing a known hydroforming process, the cavity
30
is pressurized with the hydraulic fluid to force the outer wall
28
into engagement with the forming surface
15
of the die portions
12
and
14
. The outer wall
28
is deformed such that it engages the openings
23
and
25
. Preferably, the openings
23
and
25
of the mounting members include a generally concaved annular surface such that the deformed outer wall
28
of the tubular member
26
locates the mounting members
22
and
24
axially on the tubular member
26
.
The tubular member
26
and mounting members
22
and
24
may respectively include first
36
and second
38
interlocking features. For example, the interlocking features may be complementary and recesses or splines, as shown in FIG.
5
A. Alternatively, the mounting member may include a hole
40
that receives a protrusion
42
formed during the hydroforming process. The interlocking features
36
and
38
ensure that the mounting members
22
and
24
do not move axially or rotationally relative to the tubular member
26
.
Referring to
FIG. 4
, a material
34
such as a polymeric film or adhesive may be arranged between the mounting members
22
and
24
and the tubular member
26
to prevent corrosion. The material
34
may be selected such that a seal is created between the bearing shoulder sleeve
22
and the tubular member
26
to prevent leakage of lubricant past the bearing shoulder sleeve
22
.
In this manner, a shoulder for the bearing assembly may be provided without machining the axle. Moreover, the brake flange
24
may be secured to the axle without welding. Post heat treatment of the axle assembly may not be necessary with the present invention hydroforming process.
The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
Claims
- 1. A method of forming an axle comprising the steps of:a) arranging an axle component mounting member into a die assembly; b) arranging a tubular member in the die assembly within an opening in the mounting member; c) pressurizing a cavity within the tubular member; and d) deforming a portion the tubular member into engagement with mounting member to affix the mounting member to the tubular member.
- 2. The method according to claim 1, wherein the mounting member is a bearing shoulder sleeve.
- 3. The method according to claim 1, wherein the mounting member is a brake flange.
- 4. The method according to claim 1, further including the step of arranging a material between the mounting component and the tubular member for preventing corrosion therebetween.
- 5. The method according to claim 1, wherein the mounting member includes a recess, and step d) includes deforming a portion of the tubular member into the recess.
- 6. The method according to claim 5, wherein the recess is at least one hole.
- 7. The method according to claim 5, wherein the recess is defined by a splined surface arranged about the tubular member.
- 8. The method according to claim 1, further including the step of hydroforming the tubular member into a desired axle shape.
- 9. The method according to claim 1, wherein the opening of the mounting member is defined by a generally concave surface.
- 10. Tho method according to claim 1, wherein step (d) is performed in response to performing step (c).
US Referenced Citations (19)