Abstract: An apparatus (10) and die assembly (26, 30) for forming a splined power transmission member from a thin-walled blank. The apparatus (10) comprises a pair of die assemblies (26, 30), each including a supporting frame (28), first (42) and second (44) die bodies independently mounted on the supporting frame (28) in end-to-end coaxial relationship with each other, with rough (46) and finish (48) spline-forming surfaces formed on the first (42) and second (44) die bodies, respectively. The pair of die assemblies (26, 30) are supported with the spline-forming surfaces of the respective die bodies (42, 44) in spaced, oppoosed, parallel relationship to each other. A power drive mechanism sequentially moves the pair of die assemblies (26, 30) in opposed directions. The power drive means effectuates a rough spline-forming stroke and then returns the die assemblies (26, 30) to the neutral position.

Abstract: An apparatus (12) for cold sizing a round workpiece (14) having round surfaces of cylindrical shapes that are coaxial about a central axis A of the workpiece and have different diameters. A support (54,55) rotatably mounts the workpiece (14) about its central axis A between a pair of die assemblies (24a, 24b) which are spaced from each other. Each die assembly (24a,24b) includes a plurality of dies (56,58,60,62) that are respectively aligned with the round surfaces (46,48,50,52) of the workpiece (14). Movement of the die assemblies in opposite directions as each other engages sizing surfaces (66,68,70,72) of the dies with the aligned round surfaces of the workpiece to pressure size the workpiece surfaces. In one embodiment of the sizing apparatus (12), the die assemblies (24a, 24b) have elongated shapes and are moved rectilinearly in a parallel relationship to each other to perform the sizing.

Abstract: A power transmission member (42), as well as apparatus (10,110,210) and method for forming the power transmission member (42) from a thin-walled blank. The apparatus (10,110,210) comprises a pair of opposed toothed dies (26,30;112,114;138,140). A toothed mandrel (40) is rotatably supported between the dies and received within the sleeve portion (46), flatly engaging an annular end wall (44) of the member. The dies (26,30;112,114;138,140) and mandrel (40) have chamfered surfaces (68,70), respectively, for forming a chamfered flange (66) on the power transmission member (42) as the toothed surfaces of the dies are relatively moved during the splining operation. A loading notch (122) is formed intermediately along the toothed work surfaces of each die member (112,114;138,140) for receiving a blank to be splined when the notches (122) are vertically aligned with one another in a neutral or loading position on opposite sides of the mandrel.

Abstract: An apparatus for forming splines in a first portion (22) of a shaft (13) of a workpiece (12) and a thread in a second portion (24) of the shaft (13) which has a smaller cross sectional diameter than the first portion (22), the apparatus including supports (26,28) for rotatably supporting the shaft (13) about the longitudinal axis A thereof and a pair of forming assemblies (36,36',38,38') mounted for movement with the workpiece (12) therebetween. The apparatus (10) is characterized by the forming assemblies (36,36',38,38') including oppositely opposed dies for simultaneously forming the splines in the first portion (22) of the shaft (13) having the larger cross sectional diameter and threads in the second portion (24) having the smaller cross sectional diameter in a single pass of the dies over the shaft (13).

Abstract: A power transmission member (42), as well as apparatus (10,110,210) and method for forming the power transmission member (42) from a thin-walled blank. The apparatus (10,110,210) comprises a pair of opposed toothed dies (26,30;112,114;138,140). A toothed mandrel (40) is rotatably supported between the dies and received within the sleeve portion (46), flatly engaging an annular end wall (44) of the member. The dies (26,30;112,114;138,140) and mandrel (40) have chamfered surfaces (68,70), respectively, for forming a chamfered flange (66) on the power transmission member (42) as the toothed surfaces of the dies are relatively moved during the splining operation. A loading notch (122) is formed intermediately along the toothed work surface of each die member (112,114;138,140) for receiving a blank to be splined when the notches (122) are vertically aligned with one another in a neutral or loading position on opposite sides of the mandrel.

Abstract: A method for forming a power transmission member (42) from a thin-walled blank. The apparatus (10, 110, 210) comprises a pair of opposed toothed dies (26, 30; 112, 114; 138, 140). Initial opposed movement of dies (112, 114; 138, 140) from a loading position simultaneously engages opposing pairs of similar rough forming teeth (124, 126, 128) and mandrel teeth (48) with a sleeve portion (46) therebetween, rough forming splines therein. The dies (112, 114; 138, 140) are then moved in the reverse direction, simultaneously engaging opposed pairs of similar finishing teeth (130, 132) and the mandrel teeth (48) with the sleeve (46) therebetween to finish forming the splines (64) therein. Opposed rows of raised synchronizing teeth (142) respectively extend along the toothed work surfaces of the dies and mandrel and are spaced inwardly therefrom, meshing together to rotate the mandrel and coordinate the relative movement of the dies and mandrel during a splining operation.

Abstract: An apparatus (10) and die assembly (26,30) for forming a splined power transmission member from a thin-walled blank. The apparatus (10) comprises a pair of die assemblies (26,30), each including a supporting frame (28), first (42) and second (44) die bodies independently mounted on the supporting frame (28) in end-to-end coaxial relationship with each other, with rough (46) and finish (48) spline-forming surfaces formed on the first (42) and second (44) die bodies, respectively. The pair of die assemblies (26,30) are supported with the spline-forming surfaces of the respective die bodies (42,44) in spaced, opposed, parallel relationship to each other. A power drive mechanism sequentially moves the pair of die assemblies (26,30) in opposed directions. The power drive means effectuates a rough spline-forming stroke and then returns the die assemblies (26,30) to the neutral position. Subsequently, there is a finish spline-forming stroke and then return to the neutral position.

Abstract: An apparatus for forming splines in a first portion (22) of a shaft (13) of a workpiece (12) and a thread in a second portion (24) of the shaft (13) which has a smaller cross sectional diameter than the first portion (22), the apparatus including supports (26,28) for rotatably supporting the shaft (13) about the longitudinal axis A thereof and a pair of forming assemblies (36,36',38,38') mounted for movement with the workpiece (12) therebetween. The apparatus (10) is characterized by the forming assemblies (36,36',38,38') including oppositely opposed dies for simultaneously forming the splines in the first portion (22) of the shaft (13) having the larger cross sectional diameter and threads in the second portion (24) having the smaller cross sectional diameter in a single pass of the dies over the shaft (13).

Abstract: A method and apparatus (12) for cold sizing a round workpiece (14) having round surfaces of cylindrical shapes that are coaxial about a central axis A of the workpiece and have different diameters. A support (54,55) rotatably mounts the workpiece (14) about its central axis A between a pair of die assemblies (24a, 24b) which are spaced from each other. Each die assembly (24a,24b) includes a plurality of dies (56,58,60,62) that are respectively aligned with the round surfaces (46,48,50,52) of the workpiece (14). Movement of the die assemblies in opposite directions as each other engages sizing surfaces (66,68,70,72) of the dies with the aligned round surfaces of the workpiece to pressure size the workpiece surfaces. In one embodiment of the sizing apparatus (12), the die assemblies (24a, 24b) have elongated shapes and are moved rectilinearly in a parallel relationship to each other to perform the sizing.

Abstract: A machine (10) disclosed incorporates spline rolling apparatus (12) having a pair of racks (30) of a construction that permits precise rolling of coarse pitch splines (45). Each rack (30) includes a toothed forming face (32) and a flat base surface (58) as well as a flat side support surface (60) that cooperatively provide accurate location of the rack during the spline rolling. Teeth (56) spaced along the toothed forming face have tapered ends such that a rotatably supported workpiece (14) which is moved axially between the racks (30) during reciprocal driving thereof is progressively formed with the coarse pitch splines (45) without excessively loading the teeth. Both straight and curved tapers are disclosed, preferably on both ends of each tooth, and the teeth are disclosed as being both perpendicular to the direction of the rack to roll straight splines as well as angularly with respect thereto to roll helical splines.

Abstract: A method for simultaneously forming splines and an annular groove in a metal piece having a central portion and ends on each side thereof, the method including the steps of forming a substantially U-shaped annular recess (56) along the central portion of the workpiece which has a flat base and spaced sidewalls which are spaced apart to a greater distance than the side walls of the groove (82) to be formed, deforming the recess (56) to initially form a groove (82) therein, progressively and simultaneously forming splines in the ends of the workpiece and forming the groove (82) in the recess of the workpiece, and moving metal outwardly and upwardly from the recess as the groove (82) is formed to fill the remainder of the recess (56) and form the sidewalls of the groove (82).

Abstract: Apparatus for flanging and splining a thin-walled blank to make a splined and flanged power transmission member (42). A toothed mandrel (40) is rotatably supported between a pair of toothed dies (26,30; 112,114; 138,140). The dies and mandrel have chamfered surfaces (68,70) for forming a flange (66) on the thin-walled member as the toothed surfaces of the dies and mandrel are relatively moved during a spline forming operation.

Abstract: A machine (10) for forming grooves and splines in workpiece (32) including a mounting assembly (26,28,34,36) defining a support axis for rotatably supporting the workpiece (32) for rotary movement about the axis, and dies (38,40;90,92) including opposed spline forming toothed work surfaces (46) spaced on opposite sides of the support axis for forming splines therein when the work surfaces (46) are moved relative to one another. Each of the dies (38,40;90,92) include a body portion (68) having an elongated straight slot formed therein transverse to the toothed work surfaces (46). A groove forming element (48) removably mounted in the slot simultaneously deforms the workpiece to form a groove as the toothed work surfaces (46) form spline in the workpieces. The groove forming element (48) has a constant width when viewed in transverse cross section and has a portion secured in the slot and a groove forming edge extending from the slot. The edge has leading portion and a trailing portion.

Abstract: A rack (12,14) for burnishing toothed gears (16) in cooperation with another like rack so as to provide accentuated axial crowns on the burnished teeth is disclosed as having a unitary body (42) of an elongated shape with leading and trailing ends (44,46) and a toothed forming face (48) extending between the ends. The toothed forming face (48) includes a leading section a of teeth that extend parallel to a mounting surface (54) of the rack body and at least one section of inclined teeth (50) preferably embodied by an intermediate section b and a trailing section c. A fixture (60) for grinding the inclined tooth sections b and c on a pair of cooperable racks (12,14) includes a pair of inclined support surfaces (66,68) and a clamp (70) for clamping the rack bodies during the inclined tooth grinding.

Abstract: Thin-wall spline forming apparatus (20) disclosed includes toothed forming racks (24) having associated tooth pitch lines (48) and a toothed mandrel (22) having a tooth pitch circle (50) that is tangent to the forming rack pitch lines and of a diameter equal to the mean diameter of thin-wall splines (44) formed by meshing the rack and mandrel teeth with a thin-wall sleeve (38) of a power transmission member mounted on the mandrel between the meshing teeth. A mandrel drive gear (60) drives the mandrel in coordination with the forming racks (24) and is driven by a pair of drive racks (62) mounted for movement with the forming racks. Best results are achieved when the mandrel (22) has the same number of teeth (40) as the number of teeth (64) of the drive gear (60) and with the mandrel and drive gear teeth aligned with each other.

Abstract: Thin-wall sleeve splining apparatus (10) is disclosed as including a loader (22) having a radially expandable mandrel (24) which is inserted within a dual ended thin-wall sleeve (14) to secure the sleeve in preparation for splining one of its ends (12,16). A rotatable loading spindle (26) supports the expandable mandrel (24) and is moved by an actuator (28) to position the sleeve over a toothed mandrel (20) whereupon a pair of toothed dies (18) are moved in opposite directions to mesh die and mandrel teeth with the sleeve therebetween to form the thin-wall splines. After the splining, the actuator (28) moves the loading spindle (26) away from the toothed mandrel (20) for unloading of the splined sleeve. In the preferred construction of the apparatus, the toothed forming dies are embodied by elongated die racks (18) that are slidably mounted by upper and lower bases (32,34) of a splining machine (30).

Abstract: A rack (12,14) for burnishing toothed gears (16) in cooperation with another like rack so as to provide accentuated axial crowns on the burnished teeth is disclosed as having a unitary body (42) of an elongated shape with leading and trailing ends (44,46) and a toothed forming face (48) extending between the ends. The toothed forming face (48) includes a leading section a of teeth that extend parallel to a mounting surface (54) of the rack body and at least one section of inclined teeth (50) preferably embodied by an intermediate section b and a trailing section c. A fixture (60) for grinding the inclined tooth sections b and c on a pair of cooperable racks (12,14) includes a pair of inclined support surfaces (66,68) and a clamp (70) for clamping the rack bodies during the inclined tooth grinding.

Abstract: A toothed rack (22) disclosed has a toothed forming face (24) of a novel construction for forming splines (42) in a thin-wall sleeve (36) of a power transmission member (28) by meshing of the rack and a toothed mandrel (26) with the sleeve therebetween to form the splines. The toothed forming face has leading, intermediate, and trailing tooth groups (40a, 40b, 40c) that perform the splining. The pitch line tooth thickness of the leading tooth group is at least equal to and preferably greater than the pitch line tooth thickness of the trailing tooth group which has an addendum of a greater height than the leading tooth group. The teeth of the intermediate tooth group have an addendum height that is shorter than the teeth of the trailing tooth group and preferably equal to the addendum height of the leading tooth group. The pitch line tooth thickness of the leading tooth group is equal to and preferably greater than the pitch line tooth thickness of the intermediate tooth group.

Abstract: Thin-wall spline forming apparatus (20) disclosed includes toothed forming racks (24) having associated tooth pitch lines (48) and a toothed mandrel (22) having a tooth pitch circle (50) that is tangent to the forming rack pitch lines and of a diameter equal to the mean diameter of thin-wall splines (44) formed by meshing the rack and mandrel teeth with a thin-wall sleeve (38) of a power transmission member mounted on the mandrel between the meshing teeth. A mandrel drive gear (60) drives the mandrel in coordination with the forming racks (24) and is driven by a pair of drive racks (62) mounted for movement with the forming racks. Best results are achieved when the mandrel (22) has the same number of teeth (40) as the number of teeth (64) of the drive gear (60) and with the mandrel and drive gear teeth aligned with each other.

Abstract: A rack (12, 14) for burnishing toothed gears (16) is disclosed as having an elongated body of a multiple section construction that provides accentuated axial crowns to gear teeth burnished by the rack. Leading and trailing sections (36, 38) of the rack each have a tooth forming face (44) that provides the rotary support for the gear and the burnishing of the gear teeth (46) as the gear rotates between a cooperative pair of the racks. One of the toothed forming faces, preferably the trailing one, is slightly inclined with respect to the other rack section in a lateral direction along the elongated length of the body so as to provide the accentuated axial crowns on the burnished gear teeth. Both the leading and trailing rack sections are preferably mounted on a base (42) that interconnects the rack sections.