Ball nut and method of high volume manufacturing of same

A ball nut having at least one internal bearing race with a first end and a second end, and at least one recirculating crossover passage for connecting the first end with the second end to form a continuous recirculating path for a plurality of ball bearings, comprising:

• means for forming an eyelet with a helix passage for receiving the plurality of ball bearings in a flange end;
• means for defining a portion of the crossover passage in the flange end, the crossover passage in communication with the helix passage for returning the plurality of ball bearings;
• and
• means for assembling two eyelets in flange-to-flange relationship with respect to one another to define at least one raceway having a single recirculating rotational path passing through aligned portions of the crossover passage formed by the flange-to-flange relationship of the two eyelets for receiving the plurality of ball bearings.

A ball nut having at least one internal bearing race with a first end and a second end, and at least one recirculating crossover passage for connecting the first end with the second end to form a continuous recirculating path for a plurality of ball bearings, comprising:

• a first stamped part with a first portion of a groove and a first portion of the crossover passage in a first face of a first flange region from a flat metal strip for receiving the plurality of ball bearings;
• a second stamped part with a second portion of the groove and a second portion of the crossover passage in a second face of a second flange region in the flat metal strip, the second portions of the groove and crossover passage of the second part operably positionable in communication with the first portions of the groove and crossover passage of the first part for returning the plurality of ball bearings from one end of the groove to an opposite end;
• and
• the first and second stamped parts assembled in face-to-face, flange-to-flange relationship with respect to one another to define a ball nut with a continuous recirculating path for a plurality of ball bearings.

In a ball nut having at least one internal bearing race with a first end and a second end, and a crossover passage for connecting the first end and the second end to form a continuous recirculating path for a plurality of ball bearings, the improvement comprising:

• a first stamped part having a first portion of a groove and a first portion of the crossover passage formed in a first face of a first flange for receiving the plurality of ball bearings;
• a second stamped part having a second portion of the groove and a second portion of the crossover passage formed in a second face of a second flange, the second part operably positionable in face-to-face, flange-to-flange communication with the first part for returning the plurality of ball bearings from one end of the groove to an opposite end;
• and
• means for connecting the first and second parts in face-to-face, flange-to-flange relationship with respect to one another to define a ball nut with a continuous recirculating path for a plurality of ball bearings.