A new method of manufacturing a torque-transmitting component is provided. The method includes providing a flat blank to a transfer press having a plurality of stations and performing a plurality of pressing operations, in which the flat blank is formed into a cup shape, rough splines are formed on the cup shape, and the rough splines are further pressed to define smooth splines. The component includes a continuous smooth inner diameter defined by a punch of the transfer press and a plurality of smooth splines defined by a die of the transfer press. The minor diameter of the splines is not machined to form the splines.

Provided is a gear material that is for a differential ring gear or the like, and that has a relatively large shape and has spur gear teeth or helical gear teeth at an outer periphery thereof, and with which the yield of a final product is improved, the operating cost of gear cutting by a hobbing machine is reduced, and the rate of cutting is dramatically increased to reduce a machining time, whereby the total manufacturing cost can be reduced. This gear material is in the shape of a ring having an outer diameter of at least 170 mm and an outer peripheral thickness of at least 30 mm, and has, at an outer peripheral surface thereof, spur gear teeth or helical gear teeth with a machining allowance of 0.2 mm to 2.0 mm on either side thereof.

Provided is a gear material that is for a differential ring gear or the like, and that has a relatively large shape and has spur gear teeth or helical gear teeth at an outer periphery thereof, and with which the yield of a final product is improved, the operating cost of gear cutting by a hobbing machine is reduced, and the rate of cutting is dramatically increased to reduce a machining time, whereby the total manufacturing cost can be reduced. This gear material is in the shape of a ring having an outer diameter of at least 170 mm and an outer peripheral thickness of at least 30 mm, and has, at an outer peripheral surface thereof, spur gear teeth or helical gear teeth with a machining allowance of 0.2 mm to 2.0 mm on either side thereof.

A press assembly for forming outer helical splines on a blank includes an upper press shoe assembly and a die shoe assembly. The upper press shoe assembly includes an upper rotatable portion rotatable relative to an upper stationary portion. The lower portion includes a lower rotatable portion rotatable relative to a lower stationary portion. The unfinished blank is supported by the lower portion, and the upper portion is moveable into engagement with the blank. The upper rotatable portion joins with the lower rotatable portion for conjoint rotation relative to the upper and lower stationary portions via upper and lower helical meshes defined between the rotatable and stationary portions. The helical meshes convert downward force into rotation and translation of the blank into a spline forming die of the lower stationary portion to create the outer helical splines.

The invention relates to a method for creating elevations (21) in a workpiece (1) by forming techniques. In a first step, depressions (11, 12) are created, with dimensions that differ from dimensions of depressions (20) to be created between the elevations (21). In a second step, the elevations (21) are created from regions (13) between the depressions (11, 12). The invention also relates to an apparatus for implementing the method and to a product thereby created.

The invention relates to a method for creating elevations (21) in a workpiece (1) by forming techniques. In a first step, depressions (11, 12) are created, with dimensions that differ from dimensions of depressions (20) to be created between the elevations (21). In a second step, the elevations (21) are created from regions (13) between the depressions (11, 12). The invention also relates to an apparatus for implementing the method and to a product thereby created.

In a method for manufacturing a hollow wheel which includes an internal toothing and an external toothing, wherein the internal toothing is a gear toothing, a workpiece is machined by way of a stamping tool. The workpiece has a tubular section with a longitudinal axis and a first stabilisation section for the shape stabilisation of the tubular section during the machining. The tubular section is inserted into a die having an internal die toothing. The workpiece is machined on the inner side by the stamping tool so as to simultaneously produce internal and external toothing by way of the workpiece executing a rotation movement with a temporally varying rotation speed and the stamping tool executing radially oscillating movements that are synchronised with the rotation movement.

In a method for manufacturing a hollow wheel which includes an internal toothing and an external toothing, wherein the internal toothing is a gear toothing, a workpiece is machined by way of a stamping tool. The workpiece has a tubular section with a longitudinal axis and a first stabilisation section for the shape stabilisation of the tubular section during the machining. The tubular section is inserted into a die having an internal die toothing. The workpiece is machined on the inner side by the stamping tool so as to simultaneously produce internal and external toothing by way of the workpiece executing a rotation movement with a temporally varying rotation speed and the stamping tool executing radially oscillating movements that are synchronised with the rotation movement.

A press assembly for forming outer helical splines on a blank includes an upper press shoe assembly and a die shoe assembly. The upper press shoe assembly includes an upper rotatable portion rotatable relative to an upper stationary portion. The lower portion includes a lower rotatable portion rotatable relative to a lower stationary portion. The unfinished blank is supported by the lower portion, and the upper portion is moveable into engagement with the blank. The upper rotatable portion joins with the lower rotatable portion for conjoint rotation relative to the upper and lower stationary portions via upper and lower helical meshes defined between the rotatable and stationary portions. The helical meshes convert downward force into rotation and translation of the blank into a spline forming die of the lower stationary portion to create the outer helical splines.

A gear includes an inner hub formed of metal material, the inner hub having an outer surface defining a plurality of outer teeth. The gear also includes an outer ring formed of non-metal material, the outer ring having an inner diameter that is smooth. The outer ring is disposed in an interference fit with the outer teeth of the inner hub.