Abstract: A process for cold forming integral spindle-axle tubes includes placing a tubular blank within an open ended die having an extrusion die throat, and pushing the blank through the die throat with a punch. The punch is formed with a ram portion that applies pressure to the blank for moving it axially through the throat. The punch also has an extension closely fitted within the blank so that as the punch pushes the tube axially, the blank is extruded between the die throat and the extension to form a thin wall tube. After the blank is partially extruded, the punch is removed and a second blank is inserted. This second blank is then located between the punch ram portion and the trailing end of the first blank so that further movement of the punch causes the second blank to push the first blank through the die throat.

Abstract: A process for cold forming semi-float axle tubes and similar types of metal tubes which includes arranging a short, tubular blank within an open ended die having an extrusion die throat, and pushing the blank through the die throat with a punch. The punch is provided with a ram portion, for applying pressure to the blank for moving it axially, and also an extension formed in several sections of successively smaller diameter which act as mandrels for sizing the tube interior walls. As the punch pushes the tube axially through the throat, initially a middle size extension is arranged within the throat to extrude a thickened leading edge portion on the blank. Further movement of the die results in a larger extension section traveling through the throat for extruding a thin wall tubular section of considerable length, leaving a small unextruded portion of the blank still within the die. At that point, the punch is removed and a second blank is inserted within the die.

Abstract: A process for cold extrusion forming a metal tube with thickened end portions, including positioning a short, tubular blank in a die having an extrusion die throat, and pushing the blank through the die throat with a punch. The punch is formed with co-axial extension portions of successively smaller diameter. Thus, the first extension portion is closely fitted within the blank, while the second extension portion is aligned within the die throat as the punch end pushes the blank towards and through the die throat to thereby form the tube lead end thickened end portion. Further pushing of the blank by the punch takes place while the first extension is aligned with the die throat to thereby extrude the relatively thin wall middle portion of the tube. Next, the punch is removed, and a second blank is inserted within the die against the trailing end of the first blank.

Abstract: A method for cold forming metal tubes with inwardly thickened wall sections including positioning a short, tubular blank in a die having an extrusion die throat, and pushing the blank through the die throat with a punch. The punch is formed with a co-axial mandrel-like extension which fits within the blank and die throat. The extension is formed of co-axial sections of successively smaller diameter. Thus, as the punch pushes the end of the blank to move the blank through the die throat, a narrower diameter extension section fits within the die throat to extrude a thickened end portion. Thereafter, continued punch movement positions a wider mandrel forming extension section within the die throat to extrude a thin wall tube section.

Abstract: An improved method for manufacturing a steering knuckle and spindle unit for a heavy duty vehicle, such as a truck, including forming the spindle, separately forming the knuckle, and finally welding the knuckle and spindle together to form an integral unit. The spindle is a hollow elongated metal tube preferably cold formed. The knuckle is formed by forging and a bore is machined or pierced in the knuckle to be aligned with the hollow portion of the spindle. The knuckle and spindle are then welded together such as by spin or inertia or electron beam welding to form an integral unit.