Axle bolt

An axle bolt comprising:

• an elongated body having a first end, a second end and an external surface;
• an end cap integrally formed with the first end of the elongated body, the end cap having an end face defining a plane, the end face having a cold formed recess defined therein with a bottom surface spaced from the plane, the bottom surface of the recess being conically tapered with respect to the plane and having a central low spot that is furthest from the plane of the end face, the recess further comprising a side wall extending between the bottom surface of the recess and the end face of the end cap, the transition between the side wall and the end face being a non-square edge;
• an axial passage defined in the bolt, the passage having an open end defined at the central low point of the bottom surface of the recess, the passage extending from the open end axially along the elongated body toward the second end, and terminating before the second end, the open end of the passage having a predetermined inside diameter;
• a transverse passage defined in the bolt, the transverse passage extending radially from the axial passage to the external surface of the elongated body;
• a grease fitting having a generally cylindrically shaped engagement portion having a barbed projection defined thereon, the barbed projection having a predetermined outside diameter, the grease fitting being driven into the open end of the axial passage such that the engagement portion engages the open end of the axial passage;
• wherein the predetermined inside diameter and predetermined outside diameter are chosen such that once the grease fitting is driven into the open end of the axial passage, the fitting can withstand 3000 psi without becoming disengaged from the opening;
• wherein the conically tapered bottom surface of the recess extends radially away from the grease fitting so as to define substantially the entire width of the recess;
• and
• wherein the recess is sufficiently deep that the grease fitting does not extend beyond the plane of the end face.

A method of forming an axle bolt, comprising the steps of:

• forming a bolt having an end cap and an elongated generally cylindrical body extending therefrom to a second end, the body having an external surface, the end cap having an end face defining a plane;
• cold forming a recess in the end face of the end cap, the cold formed recess having a conically tapered bottom surface with a central low point that is furthest from the plane of the end face;
• forming an axial passage having an open end defined at the central low point of the bottom surface of the cold formed recess and extending along the elongated body toward the second end and terminating before the second end;
• forming a transverse passage extending radially between the axial passage and the external surface of the body;
• providing a grease fitting having a generally cylindrically shaped engagement portion with a barbed projection defined thereon;
• and
• driving the engagement portion of the grease fitting into the open end of the axial passage such that the engagement portion engages the open end of the axial passage;
• wherein after the engagement portion of the grease fitting is driven into the open end of the axial passage, the conically tapered bottom surface of the recess extends radially away from the grease fitting so as to define substantially the entire width of the recess.