Abstract: A method for manufacturing a combined driveshaft tube and yoke assembly includes the initial step of orienting a first component having a first wall thickness and a second component having a second wall thickness to define an overlap region. The first and second components may have the same or different wall thicknesses, may be formed from the same or different materials, and may have the same or different lengths. Portions of the first and second components are deformed to provide the overlap region with a third wall thickness that is the sum of the first wall thickness and the second wall thickness. Lastly, a pair of yoke arms having respective openings therethrough is formed in the overlap region to provide a combined driveshaft tube and yoke assembly. A pair of combined driveshaft tube and yoke assembly can also be manufactured in accordance with this method.

Abstract: A method for manufacturing a combined driveshaft tube and yoke assembly includes the initial step of providing a workpiece having a first end portion, a central portion, and a second end portion. The workpiece may have a varying wall thickness, such as by providing the first end portion and the second end portion with a first wall thickness and the central portion with a second wall thickness that is greater than the first wall thickness. If desired, the central portion of the workpiece may be provided with a ridge that extends about the circumference thereof. Additionally, the central portion of the workpiece may be provided with a plurality of protrusions. The workpiece may be hollow can be deformed to the desired shape by hydroforming or magnetic pulse forming. The central portion of the workpiece is divided, such as along the circumferential ridge, to provide a pair of combined driveshaft tube and yoke assemblies.

Abstract: A method for manufacturing a combined driveshaft tube and yoke assembly includes the initial step of providing a workpiece having a first portion defining a first wall thickness and a second portion defining a second wall thickness that is different from the first wall thickness. The first and second portions can be first and second sections that are separate from one another and joined together. Alternatively, the first and second portions can be formed integrally with one another. A pair of yoke arms having respective openings therethrough are formed in the first portion of the workpiece to provide a combined driveshaft tube and yoke assembly. A bearing bushing may be disposed in each of the openings. Alternatively, the yoke arms can have respective flanged openings formed therethrough.