An assembly having a clutch collar, a clutch collar, and a method of manufacturing a clutch collar. The clutch collar may have clutch collar teeth that are continuously curved in a direction that extends away from an axis. A dovetail profile may be provided with the clutch collar teeth.

An assembly having a clutch collar, a clutch collar, and a method of manufacturing a clutch collar. The clutch collar may have clutch collar teeth that are continuously curved in a direction that extends away from an axis. A dovetail profile may be provided with the clutch collar teeth.

A method wherein a cutting or grinding chamfering tool (25) is guided along the face width of a gear (12, 23, 52) through one tooth slot (8) (e.g. from heel to toe) while it contacts the topland corners (10, 1 1) of the respective concave and convex tooth flanks of adjacent teeth (2, 4). The tool moves to an index position, the gear is indexed to the next tooth slot position and the tool moves through the tooth slot (e.g. from the toe to the heel). The cycle is repeated until all topland corners are chamfered.

A method for forming welded assembly. The method includes: providing a gear workpiece; forming a joining section on the gear workpiece that defines a weld interface; applying a material to the outside surface of the gear workpiece including the joining section; cutting a plurality of teeth in the material-covered gear workpiece, each of the plurality of teeth having first and second flanks and a root, wherein the material does not reside on any one of the first flanks, the second flanks and the roots; heat treating the gear workpiece to harden the teeth; and finishing the heat-treated gear workpiece in a finishing process to form a finished ring gear, the finishing process comprising at least one of a turning operation and a lapping operation; wherein the material is disposed over the weld interface on the finished ring gear. A welded assembly is also provided.

A method for forming welded assembly. The method includes: providing a gear workpiece; forming a joining section on the gear workpiece that defines a weld interface; applying a material to the outside surface of the gear workpiece including the joining section; cutting a plurality of teeth in the material-covered gear workpiece, each of the plurality of teeth having first and second flanks and a root, wherein the material does not reside on any one of the first flanks, the second flanks and the roots; heat treating the gear workpiece to harden the teeth; and finishing the heat-treated gear workpiece in a finishing process to form a finished ring gear, the finishing process comprising at least one of a turning operation and a lapping operation; wherein the material is disposed over the weld interface on the finished ring gear. A welded assembly is also provided.

An assembly having a clutch collar, a clutch collar, and a method of manufacturing a clutch collar. The clutch collar may have clutch collar teeth that are continuously curved in a direction that extends away from an axis. A dovetail profile may be provided with the clutch collar teeth.

An assembly having a clutch collar, a clutch collar, and a method of manufacturing a clutch collar. The clutch collar may have clutch collar teeth that are continuously curved in a direction that extends away from an axis. A dovetail profile may be provided with the clutch collar teeth.

A method and cutting tool for producing spiral toothed face couplings whereby a two-part cutter and a two-part machine tool spindle are not needed. The process includes a set-over between the cutting of convex (41) and concave (43) tooth surfaces and the tool (59) comprises inside and outside cutting blades positioned in a single cutter head blade slot (57) and separated from one another by a blade spacing angle (51).

An automotive driveline disconnect assembly includes a first clutch part and a second clutch part, and is designed and constructed to preclude an occupant-audible noise from being made between components of the disconnect assembly. The preclusion of the occupant-audible noise can be effected via one or more dampers, a non-flat tooth profile, or a combination of these measures. The disconnect assembly can be equipped in a larger automotive driveline component such as a power transfer unit (PTU), a final drive unit (FDU), a rear drive module (RDM), or an electronic differential locker (EDL).

A continuous semi-completing method for machining the tooth flanks of a face coupling workpiece using a gear cutting tool having multiple blades. Exemplary methods include a) setting of a first machine setting, wherein an inner cutting edge of an mth blade of the gear cutting tool machines a convex flank of a first tooth gap, and an inner cutting edge of a further blade machines a convex flank of a following tooth gap, until all convex flanks of all tooth gaps are finish machined, and b) setting of a second machine setting wherein an outer cutting edge of an nth blade of the gear cutting tool machines a concave flank of a tooth gap, and an outer cutting edge of a further blade machines a concave flank of a following tooth gap, until all concave flanks of all tooth gaps are finish machined.