Abstract: A differential mechanism includes a case including first and second portions, the first portion including a first surface interrupted by recesses, the second portion including a second surface interrupted by second recesses, contacting the first surface, and secured to the first portion, a pin extending though the recesses, and a ring gear secured to the portions and overlapping the surfaces and the pin.

Abstract: A differential mechanism includes a case including first and second portions, the first portion including a first surface interrupted by recesses, the second portion including a second surface interrupted by second recesses, contacting the first surface, and secured to the first portion, a pin extending though said recesses, and a ring gear secured to said portions and overlapping said surfaces and said pin.

Abstract: A differential assembly includes a first case portion, a second case portion secured to the first case portion, the first case portion and the second case portions enclosing a cavity and supported for rotation about a first axis, a spider pin located within and extending beyond the cavity at an axial position to engage the ring gear and secured to at least one of the first case portion and the second case portion for rotation therewith, and a ring gear secured to at least one of the first case portion and the second case portion, located radially outboard of the spider pins and at the axial position of the spider pins.

Abstract: A method for manufacturing a differential assembly, comprising producing a first case portion by cold flow forming a first workpiece on a first mandrel, producing a second case portion by cold flow forming a second workpiece on a second mandrel, installing in a cavity formed in the first case portion a spider assembly including radially extending spider pins located at an axial position, pinions supported for rotation on the spider assembly, and a first side gear engaged with the pinions, installing in a cavity formed in the second case portion a second side gear engaged with the pinions, and securing the second case portion to the first case portion.

Abstract: A differential assembly includes a first case portion, a second case portion secured to the first case portion, the first case portion and the second case portions enclosing a cavity and supported for rotation about a first axis, a spider pin located within and extending beyond the cavity at an axial position to engage the ring gear and secured to at least one of the first case portion and the second case portion for rotation therewith, and a ring gear secured to at least one of the first case portion and the second case portion, located radially outboard of the spider pins and at the axial position of the spider pins.

Abstract: The present invention involves a detachable half shaft assembly of a vehicle wheel end and has a shaft bell and a disc rotor. The detachable half shaft comprises a preloaded bearing assembly and a detachable body receiving the preloaded bearing assembly. The preloaded bearing assembly has an inner surface formed through inboard and outboard ends thereof. The detachable body has an inboard interface at an inboard end and an outboard interface at an outboard end. The inboard interface is configured for connecting to the shaft bell and the outboard is configured or connecting to the disc rotor. The detachable body has a bearing receiving portion defined by the stepped boss and a roll formed base. The bearing receiving portion radially receives the inner surface of the preloaded bearing assembly.

Abstract: A planetary differential including a differential case rotatable about an axis and a method of manufacturing thereof. The differential case includes a cover, a housing, an annulus gear, and a ring gear. The differential case defines a differential cavity having a clutch cavity and a planet cavity separated by a retainer plate coupled to the housing. The modular nature of this system allows both open and torque biasing constructions in the same packaging space. The method of manufacturing the differential includes the steps of coupling a retainer plate to the housing between the clutch cavity and the axial opening, placing a planetary gear set in the planetary cavity, and fixing the housing to the annulus gear and ring gear.

Abstract: A method of forming a metal sheet workpiece into a three-dimensional object by subjecting the workpiece to a stretch forming process along at least two strain paths having slopes of opposite sign. The strain paths define a point on a forming limit curve that is shifted substantially from a forming limit curve generated by linear strain paths. The shift in forming limit curves allows a substantially higher strain state to be reached in the workpiece in comparison to a strain state achievable using linear strain paths to attain the same strain state in flowing metal into a die cavity. The three-dimensional object is formed by flowing workpiece metal into a die cavity in a manner that controls the position and magnitude of forces restraining the periphery of the workpiece such that metal flow into the cavity takes place along the strain paths having the slopes of opposite sign.

Abstract: A method of superplastically forming a part from a blank of material. The blank is placed between opposed die structures and heated to a superplastic forming temperature. Positive fluid pressure is supplied at an increasing rate against a front surface of a blank to stretch the same into a cavity of one of the dies to begin formation of the part. A positive fluid pressure is also applied against the back surface of the blank, and acoustical energy emitted by the material of blank resulting from the occurrence of cavitation in the material is sensed. The sensing of acoustical energy is employed to control one or more of the above parameters until the formation of the cavities substantially reduces or ceases altogether.

Abstract: A method of forming an object having a relatively deep cavity from a superplastic metallic blank wherein a preform having a bottom portion and sides sloping upwardly and outwardly therefrom is first superplastically formed in a female mold. The preform is then attached to a male mold with the bottom portion of the preform in a snug fit with a top portion of the male mold which has outside dimensions equal to the cavity in the object and thereafter the preform is superplastically forced against the male mold to form the desired object.

Abstract: A method of superplastically forming a part over period of a forming cycle in which a blank of the material is provided and heated to within a certain range of temperatures. An analytical model is provided that determines locations of the blank that will deform most rapidly when forming pressure is applied. As the forming pressure is applied, the displacements are monitored at such locations while the blank is being deformed. The strain rate is then calculated and feedback control is provided to affect the strain rate at such locations that will reduce the tendency of the blank or part to cavitate.

Abstract: A blankholder having a central opening for applying pressure against the flange of a blank being drawn through a die in a draw press. The blankholder is divided into individual segments defined by its inner and outer peripheries, at least one continuous divisional line intermediate the inner and outer peripheries, and radii extending outwardly from the central axis. Each individual segment is provided with a different power source so that each segment can provide a force to the blank flange independent of the force being applied by any other segment.

Abstract: A method of removing or ejecting a part from a first die after the part has been superplastically formed in a cavity of the die at an elevated temperature such that the part sticks to the surfaces of the die. The method includes the steps of forming a flange of the part between opposed die surfaces and providing movable plate within the die cavity and a ring on the opposed surface of the first die that engages the flange and the part in the cavity in a uniform manner. The movable plate and ring are then translated away from the die surfaces to uniformly move the part from the first die after the dies are separated.