Abstract: A method of cold-forming a ball plunger blank includes providing a slug having first and second ends and backward extruding the slug at its first end to form a cavity that is defined by a wall. The method further includes forming a generally ball-shaped outer surface at the second end of the slug to final dimensions. The method also includes upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface to final dimensions.

Abstract: A green ball grinding method includes the step of supplying a green ball between a first surface of a first member and a second surface of a second member constituting a grinding apparatus, and the step of grinding the green ball between the first surface and the second surface while the green ball rotates around its own axis and in orbital motion. In the step of grinding the green ball, the step of causing the green ball grinding to proceed while applying load between the green ball and each of the first surface and the second surface, and the step of modifying the rotation axis of the green ball by reducing the load lower than in the step of causing the green ball grinding to proceed are executed alternately.

Abstract: A split bearing generally includes first and second bearing halves each having complementary partial shaft receiving portions, wherein the first and second bearing halves are substantially identically configured. The split bearing further includes fasteners for releasably coupling the first and second bearing halves together, such that when coupled, the complementary partial shaft receiving portions of the first and second bearing halves define a center bearing thru-hole for receiving a shaft, and when decoupled, the first and second bearing halves can be removed from the shaft.

Abstract: A rearview mirror assembly comprises a two-ball connector having at least one pivot ball thereon, a receiver having a plurality of fingers defining a ball receiving area, and a spring forming a circle. The spring is placed around the fingers of the receiver and the at least one pivot ball is placed into the ball receiving area of the receiver. The two-ball connector can be made of a high strength material and formed on a screw machine. The receiver does not experience a weight loss changing the torque force between ?40° Celsius and 85° Celsius, thereby substantially maintaining the torque force at a substantially constant level between ?40° Celsius and 85° Celsius.

Abstract: A ball joint assembly includes a ball stud, a generally cylindrical bearing, a housing and a retainer which retains the bearing in the housing. The generally cylindrical bearing has an upper end, a lower end, a generally cylindrical exterior sidewall, an upper flange located between the upper end and a ring groove formed in the exterior sidewall, a lower flange proximate the lower end and extending outwardly from the exterior sidewall and a socket cavity that opens toward the lower end. The ball portion of the ball stud is engaged in and retained within the socket cavity. The bearing is secured within the housing in a bore within the housing by virtue of the working of the lower flange which is located within a counterbore of the housing and the upper flange and retainer located in the ring groove. Ball joints of the type described are able to resist a pull-out force of greater than 650 lbs and up to about 1200 lbs.

Abstract: A cold forming process for manufacturing ball pivots with a ball area, a cone area and a thread area for installation in ball and socket joints by cold forming is presented, in which a ball pivot blank (1) with a shaped cone area (3) and cylindrical areas for the thread (2) and the ball (5) is manufactured at first from a bar-shaped semifinished bar stock by extrusion. The extrusion operation is followed by the forming of the ball area as another manufacturing step by means of a rolling processes. At the same time, the thread area can be formed in its final shape. Thus, the ball pivot is manufactured as a whole by cold forming only and it makes it possible to significantly increase the production output per unit of time compared to the processes known from the state of the art. At the same time, it is possible to use less expensive grades of steel, because sufficient fatigue strength of the ball pivot can be guaranteed by the cold forming.

Abstract: A process is provided for manufacturing balls, especially for ball and socket joints, as well as to a ball element for two-part ball pivots. The microalloyed carbon-manganese steel balls are manufactured by cold extrusion and subsequent grinding. Annealing can thus be completely eliminated, as a result of which a less expensive material can be used. The process makes possible a manufacture of balls especially for two-part ball pivots in a simpler manner and at a lower cost, and the surface finish and the material quality as well as the strength and the wear resistance are at the same time preserved or increased. As a result, the effort needed to manufacture the balls is reduced, and, moreover, the problem of the impact marks often developing on the ball surfaces during tempering is eliminated.

Abstract: A method comprises steps of providing bar stock, cutting the stock to form a rod-shaped blank, and stamp-forming a ball section on a first end of the blank in a transfer die. The method further includes stamp-forming an apertured flattened section on a second end of the blank to form a final product in the transfer die, and axially striking opposing ends to accurately form a length of the blank. A related transfer die apparatus includes stations for cutting and then stamp-forming a ball section on a first end of the blank, and stamp-forming an apertured flattened section on a second end of the blank to form a final product.

Abstract: An automatic system of manufacturing ball studs for vehicles which establishes various processes inline to diagnose each process and perform production and inventory control.

Abstract: A heat exchanger comprises an as-cast combined header and tank having a header portion integral with a tank portion. The cast header and tank combination has a plurality of openings originally cast in the header portion of the combination and at least one opening originally cast in the tank portion of the combination for passage of coolant into or out of the cast header and tank combination. Tubes are received in and extends through the header portion openings, and resilient grommets seal the tubes to the header portion to prevent leakage around the tubes. In making the heat exchanger, there is provided an inner mold section and outer mold section corresponding respectively to the interior and exterior configurations of a desired combined header and tank having a header portion integral with a tank portion.