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 method of manufacturing a component formed of parts capable of being separated for reassembly around another component. The process starts by taking separate, e.g., rod and cap, forgings and coining or forging them together prior to machining. The mating surfaces of the forgings are formed with a ridge-groove or a dimple/lug-recess configuration giving them a self-locating ability. After machining, the forgings are fractured along the original division to obtain two uniquely matched surfaces that need no further processing before being reassembled, e.g., to form a connecting rod for an internal combustion engine.