A method is provided for manufacturing an outer ring of a constant velocity joint including an outer ring, an inner rotational member, a torque-transmitting rolling element, and a defining member. The outer ring includes: a first inner peripheral surface to which the defining member is attached; a second inner peripheral surface; and protrusions protruding radially inward of the first inner surface and the second inner peripheral surface so as to restrict axial movement of the inner rotational member and the rolling element. The manufacturing method includes: a plastic working step involving providing a base member; and a bottom removing step involving partially removing a bottom of the base member so as to form a through hole. The plastic working step further involves providing the second inner peripheral surface. The bottom removing step further involves providing the protrusions.

A method is used to forge an outer joint member of a constant velocity universal joint. Track grooves of the outer and inner joint members each have an arc-shaped ball raceway center line having a curvature center that is not offset in an axial direction with respect to a joint center. The forging method includes performing ironing by press-fitting a cylindrical portion of one end of a shaft portion of a pre-processing material of the outer joint member including the shaft portion and the cylindrical portion into a die hole of a die while a punch set that is radially expandable and contractable is fitted to an inner peripheral surface of the cylindrical portion. The punch set includes punches and a punch base to guide the punches to enable advancing and retreating. Each of the punches has a pair of forming surfaces for forming the adjacent track grooves.

A forging method for a shaft member includes preforming at least one of a plurality of enlarged diameter portions to obtain a semi-finished member, and forming a remainder of the enlarged diameter portions in the semi-finished member using a mold. The mold includes a punch, split dies, and a workpiece receiving member. The forming of the remainder of the enlarged diameter portions includes allowing the semi-finished member having the at least one of the enlarged diameter portions to be placed on the workpiece receiving member, cramping the semi-finished member in its radial direction by closing the split dies, and filling the semi-finished member into forming surfaces of the split dies by the pressure applied by the punch under the state in which the semi-finished member is cramped.

Provided is a method of manufacturing an outer joint member of a constant velocity universal joint, which is constructed by forming a cup section having track grooves, and a shaft section, and by welding a cup member and a shaft member, the method including: forming the cup member and the shaft member of medium carbon steel; preparing a cup member having a cylindrical portion and a bottom portion integrally formed by forging, and a joining end surface in a machining step; preparing a shaft member having a joining end surface formed in a machining step; bringing the joining end surface of the cup member and the joining end surface of the shaft member into abutment against each other; welding the cup member and the shaft member by radiating a beam; and performing, after the welding, an ultrasonic flaw detection-inspection step.

An inspection device inspects a joint-type outer joint member of a constant velocity universal joint that includes a cup section having a bottomed cylindrical shape and track grooves in an inner periphery thereof for torque transmitting elements, and a shaft section extending from a bottom of the cup section. The inspection device inspects the outer joint member, which is obtained through melt-welding on a cup member forming the cup section and a shaft member forming the shaft section. The inspection device includes a surface inspection unit to inspect for a defect which appears on a surface of the outer joint member due to welding, an internal inspection unit to inspect for an internal defect of a welded portion, and a recording unit to record an inspection result of the inspection. The inspection device is configured to efficiently perform in-line total inspection for the melt-welded joint-type outer joint member.

A method of manufacturing an outside joint member, the outside joint member including a cup portion in a bottomed tubular shape and a shaft portion that is a shaft-like portion extending from a bottom portion of the cup portion and that has a spline shaft having an outer peripheral surface on which spline teeth are formed, includes forging a forming material to form a shape of the cup portion and a shape of the spline shaft on the shaft portion simultaneously using a forging die.

A method of manufacturing a rotating bearing unit includes to cause one end surface in the axial direction of the forming punch (46), formed by combining a plurality of punch elements (46, 46) divided in the circumferential direction, which are displaceable in the axial direction and which are not displaceable in the circumferential direction, and having a processing teeth (44, 44) at one end surface in the axial direction, to face the other end surface of the caulking section (20) in the axial direction. In this state, rolls (30a) are rotated about the central axis () of the hub main body (8) while pressing the other end surface of the forming punch (46) in the axial direction with a pressing surface (43) of the roll (30a) having a central axis () that is inclined with respect to the central axis () of the hub main body (8).

A method of manufacturing a rotating bearing unit includes to cause one end surface in the axial direction of the forming punch (46), formed by combining a plurality of punch elements (46, 46) divided in the circumferential direction, which are displaceable in the axial direction and which are not displaceable in the circumferential direction, and having a processing teeth (44, 44) at one end surface in the axial direction, to face the other end surface of the caulking section (20) in the axial direction. In this state, rolls (30a) are rotated about the central axis () of the hub main body (8) while pressing the other end surface of the forming punch (46) in the axial direction with a pressing surface (43) of the roll (30a) having a central axis () that is inclined with respect to the central axis () of the hub main body (8).

The present invention is directed to an integral planet carrier with no joints, a method of manufacturing it and an apparatus for doing so. Such integrally manufactured components have better strength than a conventionally produced multi-piece jointed planet carriers or integral planet carriers made from casting process. The present invention provides a hot forging process which can be used for the manufacturing of the planet carrier. The manufacturing process comprises of forward extrusion of a billet followed by backward extrusion. This is followed by bending operation, which is in turn followed by a flattening operation. Post-forging heat treatment and other treatments such as shot blasting follow. Finally machining is carried out to arrive at the final integrally formed planet carrier. The forward extrusion, backward extrusion, bending and flattening operations are done on a press or hammer having sufficient energy and load capacity. Preferably these operations are performed on a hydraulic press in order to achieve the required accuracy and precision.

A method of manufacturing an outer joint member of a constant velocity universal includes forming cup and shaft members of medium carbon steel, preparing, as the cup member, a cup member having cylindrical and bottom portions integrally formed by forging, and a joining end surface formed on an outer surface of the bottom portion after the forging, preparing, as the shaft member, a shaft member having a joining end surface to be joined to the bottom portion of the cup member, and bringing the joining end surfaces of the cup and shaft members into abutment against each other. The method also includes welding the cup and shaft members from an outer side of the cup member to an abutment portion between the cup and shaft members in a radial direction of the cup member.