Abstract: Apparatus and a method disclosed for forming an axle spindle from a hollow axle blank incorporate a hollow punch having a metallic body with an inner work surface defining a work opening and a mandrel fixed within the work opening projecting toward an open end thereof from a closed end of the opening. During forming, the punch is moved relative to the axle blank in the direction the mandrel projects so that the mandrel is received within the hollow axle blank as the work surface of the punch body forms the blank about the mandrel to provide a spindle. Preferably, several punches of this type are utilized to complete the spindle forming process on the axle blank. Each punch preferably has an elongated annular shape with a round inner work surface and a round outer surface on the mandrel so that the formed spindle is of a round shape. One of the punches which causes outward material movement has an undercut on its mandrel to facilitate punch withdrawal.

Abstract: Apparatus and a method disclosed for forming an axle spindle from a hollow axle blank incorporate a hollow punch having a metallic body with an inner work surface defining a work opening and a mandrel fixed within the work opening projecting toward an open end thereof from a closed end of the opening. During forming, the punch is moved relative to the axle blank in the direction of the mandrel projects so that the mandrel is received within the hollow axle blank as the work surface of the punch body forms the blank about the mandrel to provide a spindle. Preferably, several punches of this type are utilized to complete the spindle forming process on the axle blank. Each punch preferably has an elongated annular shape with a round inner work surface and a round outer surface on the mandrel so that the formed spindle is of a round shape. One of the punches which causes outward material movement has an undercut on its mandrel to facilitate punch withdrawal.

Abstract: An axle making method and apparatus for forming a unitary tubular axle blank with an I-beam section along an intermediate axle portion and with a bifurcated axle end for supporting a wheel spindle by ball joints. Inward deformations are formed in side walls of the intermediate axle portion to form the I-beam section by apparatus including a pair of punches with opposed forming projections between which the blank is received. Apparatus for forming the bifurcated axle end incorporates cooperable female dies and male punches with complementary work surfaces for forming the projections from a notched axle blank end and with edge work surfaces on the punch for axially upsetting webbed side walls extending between the projections in order to maintain the wall thickness of the webbed side walls at least as great as the wall thickness of the intermediate axle portion.