US 6,981,324 B2
Method of manufacturing net-shaped gears for a differential assembly
Stephen L. Prucher, Detroit, Mich. (US)
Assigned to American Axle & Manufacturing, Inc., Detroit, Mich. (US)
Filed on Mar. 26, 2003, as Appl. No. 10/400,028.
Prior Publication US 2004/0192488 A1, Sep. 30, 2004
Int. Cl. B21K 1/30 (2006.01)
U.S. Cl. 29—893.34 15 Claims
OG exemplary drawing
 
15. A method for manufacturing a differential assembly, the method comprising the steps of:
hot extruding a seamless tube of metal;
cutting a length of said seamless tube to define a preform wherein said tube includes a wall having a thickness, said tube having an outer diameter to wall thickness ratio less than 4 to 1;
heating said preform;
positioning said perform on a locating pin within a die;
forging said preform in said die to define a first gear having net-shaped teeth;
hardening a portion of said net-shaped teeth of said first gear; and
rotatably mounting said first gear in a differential housing such that said net-shaped teeth of said first gear engage teeth of a second gear.