Abstract: A flange and shaft for a two-piece forged axle and method for forging same. The flange includes a hub formed concentric about a longitudinal axis wherein the hub defines an inner annular face, an outer annular face, and a bore extending therebetween. The bore includes a first tapered surface diverging from the longitudinal axis. The flange further includes an annular ring coaxial and integral with the hub as well as a locking arrangement integral with the tapered surface for mechanically coupling the flange for rotation with a shaft. Additional embodiments of the present invention include a two-piece axle having a flange generally configured as described above and a cylindrical shaft disposed in the bore of the flange. The shaft includes a first end portion having a first radial upset engaging a first locking arrangement on the flange to couple the flange for rotation with the shaft.

Abstract: A die apparatus and method for forging a workpiece into a near net shaped gear, and includes a first die having a tooth die with a near net shaped negative cavity configured therein to forge the near net shaped gear. Also, the apparatus includes an axial restriction member that sufficiently reduces axial movement of the forged gear as tooth die moves away from the first die relative to the second die. This axial resistance member enables the head portion of the gear to be removed from the first die, and more specifically, the tooth die, after the forging portion of stroke is completed.