Powder metal forging and method and apparatus of manufacture

A castellated die set for forming a constant velocity joint inner race having alternating ball races, comprising:

• a first die having a longitudinal direction and a first die mating contour with a first plurality of die mating surfaces transverse to said longitudinal direction, said first plurality of die mating surfaces including at least a first surface and a second surface, said first surface being in a first position in said longitudinal direction, said second surface being in a second position in said longitudinal direction, said first position being offset from said second position in said longitudinal direction;
• a second die having a second die mating contour with a second plurality of die mating surfaces transverse to said longitudinal direction, said second plurality of die mating surfaces including at least a third surface and a fourth surface, said third surface being in a third position complimentary to said first position, said fourth surface being in a fourth position complimentary to said second position;
• and
• wherein said first surface, said second surface, said third surface, and said fourth surface are adapted to create castellated parting interfaces and wherein each die has a feature with a longitudinal component and a lateral component, the lateral component varies in dimension and the direction that the lateral component varies in dimension in one die is opposite from the direction that the lateral component varies in the other die, wherein the alternating ball races are tracks in which shallow ends and deep ends alternate position on every other track, and wherein, for each of the first die and the second die, the positions of the first and second plurality of die mating surfaces corresponding to the adjacent tracks are offset in the longitudinal direction.

A method of making a powder metal forging that is a constant velocity joint inner race having alternating ball races, comprising the steps of:

• providing a castellated die set including a first die mateable with a second die in a longitudinal direction, said die set having at least one laterally varying internal longitudinal feature extending in said longitudinal direction from said first die to said second die, each of said first die and said second die including a castellated parting interface dissecting each said laterally varying internal longitudinal feature into a first element in said first die and a second element in said second die;
• inserting a preform in said first die;
• closing said die set by contacting said first die against said second die;
• and
• compressing a punch against said preform, said compressing step following said closing step and converting said preform to said powder metal forging;
• wherein the alternating ball races are tracks in which shallow ends and deep ends alternate position on every other track, wherein the first die and the second die have die mating surfaces transverse to the longitudinal direction, and wherein, for each of the first die and the second die, the positions of the die mating surfaces corresponding to the adjacent tracks are offset in the longitudinal direction.