Tube end forging process

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.

Dependencies are inferred from the claim text.