American Axle & Manufacturing, Inc.

Mark S Barrett

Marc M Menosky

Thomas J Oldenburg

Larry L Cramer, Deceased

Robert B Horton

A drive shaft is produced from an aluminum alloy torque tube and aluminum alloy yokes that are pressed into each end section of the torque tube and welded to the end of the torque tube. Each end section is reduced in diameter and joined to a larger central section by a transition section. The end sections and transition sections are formed by swaging the ends of an aluminum alloy tube blank radially inwardly in two stages. The transition sections include an annular rib in the form of a concentric circular band located midway between inner and outer conical portions. The annular ribs stiffen the transition sections to reduce oil canning and noise.

Method of producing a drive shaft

An aluminum drive shaft includes an aluminum alloy torque tube and aluminum alloy yokes that are pressed into each end section of the torque tube and welded to the end of the torque tube. Each end section is reduced in diameter and joined to a larger central section by a transition section. The end sections and transition sections are formed by swaging the ends of an aluminum alloy tube blank radially inwardly in two stages. The transition sections include an annular rib in the form of a concentric circular band located midway between inner and outer conical portions. The annular ribs stiffen the transition sections to reduce oil canning and noise.

Aluminum drive shaft

A universal joint for interconnecting a pair of rotating shafts and a method of assembling the universal joint. The universal joint includes a pair of yokes secured to the shafts and a cruciform for interconnecting the yokes. Both yokes are bifurcated to define a pair of laterally-spaced legs. Each leg has an aperture which includes a first bore adapted to receive a bearing cup therein and a second bore into which an end portion of the bearing cup extends. Each bearing cup rotatably supports one of four orthogonal trunions extending from the cruciform. With respect to each of the yokes, a pair of axially-aligned trunions, with bearing cups mounted thereon, are installed into the apertures so as to support the cruciform between the legs of the yoke. Thereafter, a retention member is inserted in the second bore of each aperture such that one surface of the retention member rests on the bearing cup. After the rotary axis of the first shaft is aligned with the rotary axis of the second shaft, an edge portion of the legs surrounding the second bore of each aperture is deformed to define one or more projections which engage the opposite surface of the retention member. The projections secure the retention members within the second bore of the apertures, thereby fixing the axial position of the bearing cups and trunions relative to the yoke.

Universal joint

An automotive prop shaft assembly particularly suited for coupling a transfer case to the front axle drive components comprises a tubular drive shaft having an initial uniform inner diameter relatively smaller than the outer diameter of a pair of forged insert yokes to be attached to the ends of the shaft. A section of each end of the tube is enlarged so that its inner diameter is sized to receive the yokes into the ends of the tube with an interference fit. The shaft and yokes are then welded together and weights fixed to the end sections to correct for imbalance.

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Orion, MI, United States of America

Mark S Barrett