Method for manufacturing a modified fast fade drive axle housing

In a method for manufacturing a forged drive axle housing by hot forming and welding of a steel blank of uniform thickness and having a differential receiving portion of generally convex outer curvature extending in an axial direction with an aperture in each side face thereof, two circular members each secured to an annular zone adjacent one of said apertures and two oppositely extending beam arms of rectangular cross-section which are disposed to form a transition zone at said differential receiving portion wherein said beam arms are formed by welding two half sections of substantially U-shaped cross-section together along a horizontal center line and securing said circular members to said differential receiving portions on each face and at least one of said circular members being secured adjacent one aperture by a continuous weld joint between its radially outer edge and the contiguous side face of the differential receiving portion that improvement consisting of

• hot forming at a temperature between 1350.degree. and 2100.degree. F. the axially extending convex curvature of the U-shaped cross-section to shorten the transition zone between the extending beam arms of rectangular cross-section and the differential receiving portion, the shortening measured in terms of
• (a) the curvature of the arcuate corner sections of the U-shaped sections forming a wall of the drive axle housing and having a corner section curvature being defined by a plurality of corner radii R.sub.c each of which is struck in a plane normal to the outer surface of said wall,
• (b) the axially extending convex curvature of said wall forming the differential receiving portion being defined by a first radius R.sub.1 measured from a true origin at the intersection of the vertical axis of the differential portion of the drive axle housing,
• (c) said axially extending curvature of the wall being defined by a second eccentric radius R.sub.2 measured from a displaced origin O',
• (d) said displaced origin O' being located at the vertical axis of the differential receiving portion but being displaced in a direction away from said wall,
• (e) the axially extending convex curvature of said arcuate carrier defined by R.sub.1 and the curvature of said wall defined by R.sub.2 and R.sub.3 radii both blending concavely in each transition zone into the corner sections and planar outer wall of said rectangular beam arms,
• (f) a concave blending curvature of said corner sections being defined by a blending radius R.sub.4,
• adjusting said radius R.sub.2 to displace the axially extending convexly curved wall outwardly relative to origin O to increase R.sub.c the radii of the corner sections to thereby increase said wall thickness in a direction which is normal to the horizontal center line during the hot forming step and increase the dimensions of the box section forming the beam arms while the length of the blending radii R.sub.3 and R.sub.4 is about 40-60% of the sum of the two radii R.sub.1 and R.sub.2 thereby rapidly shortening the concave transition zone in an axial direction to a value less than 1/2 of the length of the first radius R.sub.1.