Abstract: A die formed monolithic yoke assembly for a universal joint of an automotive driveline assembly subject to high torsional loads having a substantially uniformed thickness, including a cup-shaped portion, a pair of opposed lugs integral with and extending from an upper portion of the cup-shaped portion and an integral, outwardly deformed substantially continuous lip portion extending outwardly from the upper surface of the annular wall and the lugs substantially strengthening the yoke assembly particularly against torsional loads. In one embodiment, the upper end of the cup-shaped portion included concave arcuate portions on opposed sides of the lugs adjacent the lugs, such that the upper surface of the cup-shaped portion transitions from a concave surface to a convex surface strengthening the yoke.

Abstract: A method of forming a ring gear from a ring blank includes providing a mandrel having a central axis and an outer annular forming surface. The outer annular forming surface defines a plurality of forming elements having a forming element axis offset from the central axis of the mandrel. The ring blank has a ring axis and is placed over the mandrel generally aligning the central axis of the mandrel with the ring axis of the ring blank. A roll is provided having a roll axis that is generally parallel with the element axis. The roll is forced radially inwardly while circumscribing the central axis. The roll pivots around the roll axis deforming the ring blank radially inwardly forming teeth on an inner surface of the ring blank that coaxial with the element axis and offset from the mandrel axis.

Abstract: A method of forming a ring gear from a ring blank includes providing a mandrel having a central axis and an outer annular forming surface. The outer annular forming surface defines a plurality of forming elements having a forming element axis offset from the central axis of the mandrel. The ring blank has a ring axis and is placed over the mandrel generally aligning the central axis of the mandrel with the ring axis of the ring blank. A roll is provided having a roll axis that is generally parallel with the element axis. The roll is forced radially inwardly while circumscribing the central axis. The roll pivots around the roll axis deforming the ring blank radially inwardly forming teeth on an inner surface of the ring blank that coaxial with the element axis and offset from the mandrel axis.

Abstract: A driveline system for an automotive driveline system includes a transmission device, a differential device, and a universal joint having a drive shaft presenting terminal ends and interconnecting the transmission and differential devices. A yoke is connected to each of the terminal ends of the drive shaft and presents an internal surface and an external surface having generally equal thickness defined therebetween to form a dish of the yoke having a tubular monolithic structure. The yoke portion includes a bottom and a pair of spaced lugs each presenting sloping side walls for reinforcing the lugs as said yoke is rotated around a longitudinal axis.