A modular tooling die for an axle housing includes a plurality of separable and coaxially aligned die sets. Each die set may include a cam driver that is engageable with first and second cam slide assemblies. The cam slide assemblies move toward one another along an axis that extends perpendicularly to an axis along which the cam driver translates. Multiple die sets are provided for possible use in a single press depending on the particular axle housing geometry to be manufactured. A wide variety of different geometrical configurations may be formed by simply replacing one or more die sets and inserting a differently sized or shaped blank within the press. A method of manufacturing various axle housings and the associated modular tooling is described.

An axle assembly comprising a differential carrier including an upper portion coupled with a lower portion, the upper portion comprising a planar surface defining a first hollow protrusion and a second hollow protrusion. The first hollow protrusion and the second hollow protrusion each define an arcuate cavity. An input shaft is coupled with a pinion gear drivingly engaged with a ring gear at least partially disposed within the first hollow protrusion. A differential case having a first portion and a second portion is at least partially disposed in the second hollow protrusion. The ring gear is welded to an exterior surface of said differential case first portion. A plurality of axially extending slots are defined by an interior surface of the differential case first portion. An annular canister having radially extending lugs disposed on an outer surface thereof, is disposed within said differential case. The lugs are in driving engagement with the plurality of differential case slots. A plurality of apertures are radially disposed through the canister, and a plurality of pinion shafts are disposed through and drivingly engaged with the canister apertures. A pinion gear is disposed on each of the pinion shafts. A pair of side gears is in driving engagement with the pinion gears. A first output shaft is in driving engagement with one of the pair of side gears, and a second output shaft is in driving engagement with the other of the pair of side gears.

The present invention discloses a special hydraulic press for bulging pressing forming of an automobile axle housing and a pressing forming method. A hydraulic press body is a closed frame consisting of an upper cross beam, a lower cross beam, four stand columns I, II, III, and IV, four vertical pull rods I, II, III, and IV, and four transverse pull rods I, II, III, and IV, and is used for balancing a deformation force up to 3000 T in the vertical direction or the horizontal direction in the pressing forming process. During pressing forming, the downward speeds of a main hydraulic cylinder, small left and right vertical hydraulic cylinders are precisely controlled to prevent the left end, the right end and the middle of the tube blank from bending.

The present invention discloses a special hydraulic press for bulging pressing forming of an automobile axle housing and a pressing forming method. A hydraulic press body is a closed frame consisting of an upper cross beam, a lower cross beam, four stand columns I, II, III, and IV, four vertical pull rods I, II, III, and IV, and four transverse pull rods I, II, III, and IV, and is used for balancing a deformation force up to 3000 T in the vertical direction or the horizontal direction in the pressing forming process. During pressing forming, the downward speeds of a main hydraulic cylinder, small left and right vertical hydraulic cylinders are precisely controlled to prevent the left end, the right end and the middle of the tube blank from bending.

An axle assembly includes a central tube and an axle spindle. The axle spindle is fixed to the central tube. The axle spindle has a tubular first section and a tubular second section extending from the first section. The second section has an outer diameter. The second section has a bearing support surface. A tubular transition section is located between the first section and the second section. An annular shoulder portion is formed in an axial end segment of the tubular transition section adjacent the second section. The shoulder portion has at least one annular profile located in the shoulder portion between the annular shoulder surface and the bearing support surface. The annular profile is defined by a surface with a diameter not less than the outer diameter of the second section. An antilock braking system sensor bracket locator nub is integrally formed in the tubular transition section. An antilock braking system sensor bracket engages the antilock braking system sensor bracket locator nub for proper positioning of an antilock braking system sensor.

An axle assembly includes a central tube and an axle spindle. The axle spindle is fixed to the central tube. The axle spindle has a tubular first section and a tubular second section extending from the first section. The second section has an outer diameter. The second section has a bearing support surface. A tubular transition section is located between the first section and the second section. An annular shoulder portion is formed in an axial end segment of the tubular transition section adjacent the second section. The shoulder portion has at least one annular profile located in the shoulder portion between the annular shoulder surface and the bearing support surface. The annular profile is defined by a surface with a diameter not less than the outer diameter of the second section. An antilock braking system sensor bracket locator nub is integrally formed in the tubular transition section. An antilock braking system sensor bracket engages the antilock braking system sensor bracket locator nub for proper positioning of an antilock braking system sensor.

A modular tooling die for an axle housing includes a plurality of separable and coaxially aligned die sets. Each die set may include a cam driver that is engageable with first and second cam slide assemblies. The cam slide assemblies move toward one another along an axis that extends perpendicularly to an axis along which the cam driver translates. Multiple die sets are provided for possible use in a single press depending on the particular axle housing geometry to be manufactured. A wide variety of different geometrical configurations may be formed by simply replacing one or more die sets and inserting a differently sized or shaped blank within the press. A method of manufacturing various axle housings and the associated modular tooling is described.

The present invention discloses a special hydraulic press for bulging pressing forming of an automobile axle housing and a pressing forming method. A hydraulic press body is a closed frame consisting of an upper cross beam, a lower cross beam, four stand columns I, II, III, and IV, four vertical pull rods I, II, III, and IV, and four transverse pull rods I, II, III, and IV, and is used for balancing a deformation force up to 3000 T in the vertical direction or the horizontal direction in the pressing forming process. During pressing forming, the downward speeds of a main hydraulic cylinder, small left and right vertical hydraulic cylinders are precisely controlled to prevent the left end, the right end and the middle of the tube blank from bending.

The present invention discloses a special hydraulic press for bulging pressing forming of an automobile axle housing and a pressing forming method. A hydraulic press body is a closed frame consisting of an upper cross beam, a lower cross beam, four stand columns I, II, III, and IV, four vertical pull rods I, II, III, and IV, and four transverse pull rods I, II, III, and IV, and is used for balancing a deformation force up to 3000 T in the vertical direction or the horizontal direction in the pressing forming process. During pressing forming, the downward speeds of a main hydraulic cylinder, small left and right vertical hydraulic cylinders are precisely controlled to prevent the left end, the right end and the middle of the tube blank from bending.

An axle housing assembly includes an axle housing that includes a center portion and a first arm portion that extends from the center portion. The axle housing assembly further includes a wheel end housing that includes a wheel end body that extends from the first arm portion and a spindle that extends from the wheel end body.