Abstract: A device, such as an inner race of a torque converter's overrunning clutch, is formed by powder metallurgy. The race includes oil grooves and chamfers formed in each face by forging. The oil grooves on the first face open onto the chamfer. The chamfer on the second face is interrupted at the oil grooves such that each oil groove opens onto the diametral surface. A forge assembly for forming the race includes a die assembly including a discontinuous lower chamfer tool, an upper punch including groove tools and a continuous chamfer tool, and a lower punch including groove tools and radially extending teeth disposed at the oil grooves and capable of extending into the gaps of the lower chamfer tool. A method for forming the race includes employing the die assembly to forge the oil grooves and chamfers into the preform and remove flash by conventional grinding processes.

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.

Abstract: A method for manufacturing metal by a cold worked powdered metal forging process is disclosed. A certain amount of a powdered metal is measured out and then compacted into a briquette or other compact. The briquette is then sintered to form a preform. After sintering, the preform is then cold worked to increase its strength. After cold working, the preform is forged to form the desired part. The resultant part has improved fatigue life, surface finish, and metallurgical characteristics.