Abstract: A differential assembly includes one or more NVH-modifying elements that alter and/or reduce at least one of a noise, vibration, and harshness emitted from the differential assembly. The NVH-modifying element(s) are placed in engagement with the side gears of the differential assembly to modify and/or reduce the NVH of the differential assembly.

Abstract: A differential assembly includes one or more NVH-modifying elements that alter and/or reduce at least one of a noise, vibration, and harshness emitted from the differential assembly. The NVH-modifying element(s) are placed in engagement with the side gears of the differential assembly to modify and/or reduce the NVH of the differential assembly.

Abstract: A method of forming a powder metal forging, which includes the steps of providing a preform including a sintered powder metal composition; inserting the preform in at least one part of a die set having a top die and a bottom die, at least one of the top die and the bottom die defining a helical forge form therewithin; closing the die set wherein the top die is contacting the bottom die; and compressing the preform in the forge form using an upper punch including a core rod and a lower punch, the compressing step occurring after the closing step, the compressing step resulting in a formed part having a helical outer surface. The method and apparatus of the present invention is particularly advantageous when forming a powder metal forging helical outer surface and an inner contour such as a cylindrical inside diameter.

Abstract: A method and apparatus for forming a powder metal forging (B) includes a die set (A1D) for forming the powder metal forging (B) having a first die (A) complementary with a second die (D) in a longitudinal direction (ZC). The die set (A,D) has at least two features (10) of dimensions with a longitudinal component (10) and a lateral component (18), and at least the lateral component (18) varies along the longitudinal direction (ZC), at least one such feature (10) in each die (A,D). Each of the first die (A) and the second die (D) includes a castellated parting interface (12,13) dissecting the laterally varying internal longitudinal feature (10, 18) in the first die from the laterally varying feature (10, 18) in the second die (D). The castellation (12,13) in the dies (A,D) provides forged powder metal parts (B) with features of opposite drafts without trapping the part (B) in the dies (A,D).

Abstract: A one-way clutch with an outer race and an inner race is disclosed. One of the races includes at least one pawl and an engagement member for holding the at least one pawl in engagement with ratchet teeth on the other race. The contact surface of the at least one pawl or the ratchet teeth is an arcuate shape for improved load distribution. The arcuate contact surface has a radius of curvature that is greater than a radius of curvature at corners adjacent to the arcuate contact surface.

Abstract: A retainer for a one-way clutch is provided. In some embodiments, the retainer includes an annular portion with an inner circumferential surface, an outer circumferential surface and a first axial surface disposed between the inner circumferential surface and the outer circumferential surface. The first axial surface has a plurality of grooves, a second axial surface is disposed between the inner circumferential surface and the outer circumferential surface, and the second axial surface is configured to engage an outer race of the one-way clutch assembly. The retainer also includes a plurality of inner lobes that project generally radially inwardly from the inner circumferential surface, and are configured to engage an inner race of the one-way clutch assembly.

Abstract: A differential assembly, bevel gears for the assembly, and a method of making the bevel gears are disclosed. The bevel gears have a form which provides for high power density transfer.

Abstract: A method of forming a powder metal forging, including the steps of: forming a preform including a sintered powder metal composition; inserting the preform in a die set having a bottom die and a top die, the die set defining a forge form therewithin, the die set being in a closed position wherein the top die is contacting the bottom die; and compressing the preform in the forge form using an upper punch and a lower punch, the compressing step resulting in a formed part. The closed die set minimizes or eliminates flash in the formed part, particularly in the contoured surfaces, which allows the forging to be through hardened by direct quenching after the forging operation, without the need to remove hardened flash from these surfaces.

Abstract: An overrunning clutch has a first race, a second race, a set of pawls between the first race and the second race and a set of springs between the first race and the second race, one spring for each pawl and each corresponding spring biasing the corresponding pawl into a position in which the first race and the second race are engaged with each other in a driving direction and are disengaged from each other in a free wheeling direction. Each spring is received in a spring receiving recess of one of the races and biases a rearward portion of the corresponding pawl radially inwardly into a pawl receiving recess of the race.

Abstract: A retainer for a one-way clutch is provided. In some embodiments, the retainer includes an annular portion with an inner circumferential surface, an outer circumferential surface and a first axial surface disposed between the inner circumferential surface and the outer circumferential surface. The first axial surface has a plurality of grooves, a second axial surface is disposed between the inner circumferential surface and the outer circumferential surface, and the second axial surface is configured to engage an outer race of the one-way clutch assembly. The retainer also includes a plurality of inner lobes that project generally radially inwardly from the inner circumferential surface, and are configured to engage an inner race of the one-way clutch assembly.

Abstract: A differential assembly, bevel gears for the assembly, and a method of making the bevel gears are disclosed. The bevel gears have a form which provides for high power density transfer.

Abstract: A method and apparatus for forming a powder metal forging (B) includes a die set (A1D) for forming the powder metal forging (B) having a first die (A) complementary with a second die (D) in a longitudinal direction (ZC). The die set (A,D) has at least two features (10) of dimensions with a longitudinal component (10) and a lateral component (18), and at least the lateral component (18) varies along the longitudinal direction (ZC), at least one such feature (10) in each die (A,D). Each of the first die (A) and the second die (D) includes a castellated parting interface (12,13) dissecting the laterally varying internal longitudinal feature (10, 18) in the first die from the laterally varying feature (10, 18) in the second die (D). The castellation (12,13) in the dies (A,D) provides forged powder metal parts (B) with features of opposite drafts without trapping the part (B) in the dies (A,D).

Abstract: A one-way clutch with an outer race and an inner race is disclosed. One of the races includes at least one pawl and an engagement member for holding the at least one pawl in engagement with ratchet teeth on the other race. The contact surface of the at least one pawl or the ratchet teeth is an arcuate shape for improved load distribution. The arcuate contact surface has a radius of curvature that is greater than a radius of curvature at corners adjacent to the arcuate contact surface.

Abstract: A method of forming a powder metal forging, including the steps of: forming a preform including a sintered powder metal composition; inserting the preform in a die set having a bottom die and a top die, the die set defining a forge form therewithin, the die set being in a closed position wherein the top die is contacting the bottom die; and compressing the preform in the forge form using an upper punch and a lower punch, the compressing step resulting in a formed part. The closed die set minimizes or eliminates flash in the formed part, particularly in the contoured surfaces, which allows the forging to be through hardened by direct quenching after the forging operation, without the need to remove hardened flash from these surfaces.

Abstract: An overrunning clutch has a first race, a second race, a set of pawls between the first race and the second race and a set of springs between the first race and the second race, one spring for each pawl and each corresponding spring biasing the corresponding pawl into a position in which the first race and the second race are engaged with each other in a driving direction and are disengaged from each other in a free wheeling direction. Each spring is received in a spring receiving recess of one of the races and biases a rearward portion of the corresponding pawl radially inwardly into a pawl receiving recess of the race.

Abstract: A freewheeling clutch includes torque transmitting elements disposed between an inner race and an outer race. The elements include active surfaces that may be defined by an angularly variable radius of curvature that varies with respect to roll angle at an increasing rate, such as an equiangular spiral, to form a constant strut angle as the elements move between a freewheeling and an engaged position.

Abstract: A freewheeling clutch includes torque transmitting elements disposed between an inner race and an outer race. The elements include active surfaces that may be defined by an angularly variable radius of curvature that varies with respect to roll angle at an increasing rate, such as an equiangular spiral, to form a constant strut angle as the elements move between a freewheeling and an engaged position.