Method for forming a lightweight flanged axle shaft

Abstract

A method for forming a lightweight flanged axle shaft particularly for use within automotive vehicles for transmitting power from a power source, such as the differential, to a driven wheel. The method includes extruding a tubular blank through a die throat by pushing the blank through the die throat and causing the blank to collapse inwardly around a mandrel-like member located within the die throat to thereby form an elongated, thin wall, hollow tube. A flange member, which is separately stamped out of metal, is formed with a disk-like flange and an integral central tubular-shaped hub whose free edge is of approximately the same diametrical size and thickness as the end of the shaft. The flange hub and the shaft end are welded together, face to face, by engaging the two and rapidly spinning one relative to the other to generate sufficient heat to fuse them together upon discontinuance of the rotation. This produces a one-piece, long, hollow, thin wall, lightweight, hollow shaft with a hollow flange having a hollow flange hub integrated with the shaft end. The opposite end of the shaft is configured, such as with spline teeth, for fastening that shaft end to a drive or driven member while the flange at the opposite end of the shaft is fastened to the opposite drive or driven member.