A method for manufacturing a hollow vehicle frame part includes: removing material from a first side of a first billet to create a first inner shape of a target vehicle frame such a substantially angled faying surface remains adjacent to the first inner shape; removing material from a first side of a second billet to create a second inner shape, such that a substantially angled faying surface is left on the first side of the second billet adjacent to the second inner shape; bonding the first and second billets together at the faying surfaces such that the first and second inner shapes face each other and such that the angled faying surfaces together form a bevel-type joint; after bonding, removing material by machining from the second sides of the first and second billets to create target outer shape of the vehicle frame part.

A cylinder head material of an engine is casted (Step S1). Next, the cylinder head material is machined (Step S2). Next, a heat shielding film is formed on a ceiling surface of the cylinder head material (Step S3). Next, the film thickness of the heat shielding film is measured (Step S4). Next, a rank of a piston to be combined with the ceiling surface is selected (Step S5). The rank of the piston selected in Step S5 is a rank according to depth of a cavity. Next, the rank of the piston selected in Step S5 is stamped on the cylinder head (Step S6).

A method of manufacturing a transmission case housing is provided wherein a minimum quantity of lubrication as a compressed air/oil mist is supplied as the housing is rough bored and face milled. The transmission case defines a plurality of transmission fluid drainage holes for draining transmission fluid from the transmission when installed in a vehicle. The housing is positioned with the fluid drainage holes below a central axis of the housing and a plurality of internal bores and faces are bored and face milled on the housing. The compressed air/oil mist is sprayed from the cutting head to cool and lubricate the boring and face milling tools. Machining chips are blown off the rough bored housing through the fluid drainage holes.

A method of manufacturing a transmission case housing is provided wherein a minimum quantity of lubrication as a compressed air/oil mist is supplied as the housing is rough bored and face milled. The transmission case defines a plurality of transmission fluid drainage holes for draining transmission fluid from the transmission when installed in a vehicle. The housing is positioned with the fluid drainage holes below a central axis of the housing and a plurality of internal bores and faces are bored and face milled on the housing. The compressed air/oil mist is sprayed from the cutting head to cool and lubricate the boring and face milling tools. Machining chips are blown off the rough bored housing through the fluid drainage holes.

Tube forming methods can be used for efficient transition in the production of tubes having varying thickness. Material used to form consecutive tubes may have the same thickness along a separation plane separating a first discrete section from a second discrete section of the material, and the first discrete section and the second discrete section may each have varying thickness in a feed direction of the material. With such a thickness profile, the first discrete section of the material may be formed into a first cylinder having varying thickness and separated from the second discrete portion as the second discrete section is formed into a second cylinder having varying thickness. In particular, the transition between the first cylinder and the second cylinder may be achieved without scrap and/or interruption, resulting in cost-savings and improvements in production throughput associated with forming tubes having varying thickness.

A method of producing a rotor of a charging apparatus may include the steps of providing at least one compressor wheel and a turbine wheel. The compressor wheel and the turbine wheel may each include a bearing section having a radial bearing surface at a longitudinal end for mounting a bearing housing. At least one of the radial bearing surfaces may include a radial oversizing corresponding to a rotationally asymmetric geometry between at least the bearing section of the compressor wheel and the bearing section of the turbine wheel. The method may include the step of assembling the compressor wheel, the turbine wheel and each bearing section together to form a unitary structure, and machining the at least one of the radial bearing surfaces to reduce the respective radial oversizing until each of the radial bearing surfaces are rotationally symmetrical with respect to each other.

A method of producing a rotor of a charging apparatus may include the steps of providing at least one compressor wheel and a turbine wheel. The compressor wheel and the turbine wheel may each include a bearing section having a radial bearing surface at a longitudinal end for mounting a bearing housing. At least one of the radial bearing surfaces may include a radial oversizing corresponding to a rotationally asymmetric geometry between at least the bearing section of the compressor wheel and the bearing section of the turbine wheel. The method may include the step of assembling the compressor wheel, the turbine wheel and each bearing section together to form a unitary structure, and machining the at least one of the radial bearing surfaces to reduce the respective radial oversizing until each of the radial bearing surfaces are rotationally symmetrical with respect to each other.

A method for machining toothed and hardened work wheels, includes: mounting a work wheel that is hardened and pre-toothed with an allowance onto a workpiece spindle; removing at least 50% of the allowance by means of gear skiving with a skiving wheel that is rotatably driven by a tool spindle; precision-machining the work wheel in unchanged tension by means of a honing wheel. The forward movement occurs during gear skiving in the extension direction of the toothing. The delivery of the workpiece that is moved in an oscillating manner in the extension direction of the toothing occurs during honing in the radial direction. The skiving wheel and the honing wheel are driven by a common tool spindle. A device for carrying out the method includes a workpiece spindle, which is driven to rotate, and a tool spindle, which carries a combination tool having a skiving wheel and a honing wheel.

A method for machining toothed and hardened work wheels, includes: mounting a work wheel that is hardened and pre-toothed with an allowance onto a workpiece spindle; removing at least 50% of the allowance by means of gear skiving with a skiving wheel that is rotatably driven by a tool spindle; precision-machining the work wheel in unchanged tension by means of a honing wheel. The forward movement occurs during gear skiving in the extension direction of the toothing. The delivery of the workpiece that is moved in an oscillating manner in the extension direction of the toothing occurs during honing in the radial direction. The skiving wheel and the honing wheel are driven by a common tool spindle. A device for carrying out the method includes a workpiece spindle, which is driven to rotate, and a tool spindle, which carries a combination tool having a skiving wheel and a honing wheel.

A heterogeneous composite consisting of near-nano ceramic clusters dispersed within a ductile matrix. The composite is formed through the high temperature compaction of a starting powder consisting of a core of ceramic nanoparticles held together with metallic binder. This core is clad with a ductile metal such that when the final powder is consolidated, the ductile metal forms a tough, near-zero contiguity matrix. The material is consolidated using any means that will maintain its heterogeneous structure.