Abstract A unitary tubular axle (12) is formed to include an end (18) having a support section (22) of a completely solid cross section located between a generally vertical kingpin bore (24) and a tubular intermediate portion (16) of the axle. Both ends (18) of the tube are formed with such an end construction to provide a unitary front axle for both wheels. Forming proceeds by initially reducing the size of the outer tube diameter at an end thereof while maintaining roundness. Axial forging of the tube end preferably by a closed die having a semispherical closed end then provides an axle end having a solid cross section and a distal semispherical shape. Subsequent axial forging of the solid tube end by another closed die then provides upper and lower projections (26, 28) in which upwardly and downwardly facing holes are then forged to increase the width thereof while leaving a web between inner ends of the holes. A final boring operation through the upper and lower projections along the respective holes thereof and through the web then provides the kingpin bore which is located on the opposite side of the solid support section from the intermediate tubular portion of the axle. Bending of the axle end provides an upawardly extending wing section (20) from which the solid support section projects generally horizontally.
A process for making a solid end tube from a tube with a hollow end of a round shape, the process comprising: moving a closed die having a round opening including a semispherical inner end in a rectilinear path without rotation toward the hollow tube end to axially forge said tube end within the die opening to a solid condition while maintaining the roundness thereof and concomitantly forging a distal semispherical shape.
Claim 2
Dependent Claim
72 words
A process for making a solid end tube from a tube with a hollow end of a round shape, the process comprising: moving a closed die having a round opening including a semispherical inner end in a rectilinear path without rotation toward the hollow tube end to axially forge said tube end within the die opening to a solid condition while maintaining the roundness thereof and concomitantly forging a distal semispherical shape.
Claim 3
Dependent Claim
102 words
A process for making an axle with a solid end from a round tube with a hollow end, the process comprising: moving a closed die having a round opening including a semispherical inner end in a rectilinear path without rotation toward the hollow tube end to axially forge said tube end within the die opening while maintaining the roundness thereof to provide an axle end having a solid cross section and a distal semispherical shape; thereafter axially forging the solid axle end to include upper and lower projections; and finally forming a generally vertical kingpin bore through the upper and lower projections.
Claim 4
Dependent Claim
102 words
A process for making an axle with a solid end from a round tube with a hollow end, the process comprising: moving a closed die having a round opening including a semispherical inner end in a rectilinear path without rotation toward the hollow tube end to axially forge said tube end within the die opening while maintaining the roundness thereof to provide an axle end having a solid cross section and a distal semispherical shape; thereafter axially forging the solid axle end to include upper and lower projections; and finally forming a generally vertical kingpin bore through the upper and lower projections.
Claim 5
Dependent Claim
130 words
A process for making an axle from a round tube, the process comprising: initially reducing the size of the outer tube diameter at an end of the tube while maintaining the roundness thereof; subsequently axially forging said tube end while maintaining the roundness thereof to provide an axle end having a completely solid cross section and a distal semispherical shape; thereafter axially forging the solid axle end to provide upper and lower projections; simultaneously forging upwardly and downwardly facing holes in the upper and lower projections while concomitantly increasing the transverse width thereof and leaving a web therebetween; and finally boring through the upper and lower projections along the respective holes thereof and through the web therebetween to thereby provide a bore for mounting a kingpin on the axle end.
Claim 6
Dependent Claim
130 words
A process for making an axle from a round tube, the process comprising: initially reducing the size of the outer tube diameter at an end of the tube while maintaining the roundness thereof; subsequently axially forging said tube end while maintaining the roundness thereof to provide an axle end having a completely solid cross section and a distal semispherical shape; thereafter axially forging the solid axle end to provide upper and lower projections; simultaneously forging upwardly and downwardly facing holes in the upper and lower projections while concomitantly increasing the transverse width thereof and leaving a web therebetween; and finally boring through the upper and lower projections along the respective holes thereof and through the web therebetween to thereby provide a bore for mounting a kingpin on the axle end.