Differential mechanism assembly

Abstract

A method for manufacturing a differential assembly, comprising producing a first case portion by cold flow forming a first workpiece on a first mandrel, producing a second case portion by cold flow forming a second workpiece on a second mandrel, installing in a cavity formed in the first case portion a spider assembly including radially extending spider pins located at an axial position, pinions supported for rotation on the spider assembly, and a first side gear engaged with the pinions, installing in a cavity formed in the second case portion a second side gear engaged with the pinions, and securing the second case portion to the first case portion.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]This invention relates generally to a differential gear mechanism for transmitting rotary power from a power source to the wheels of a vehicle so that the wheels can rotate at mutually differential speeds and to the manufacture of the differential mechanism.[0003]2. Description of the Prior Art[0004]A differential mechanism transmits rotary power differentially to output shafts from a ring gear driven by an external power source, such as an internal combustion engine or electric motor. The differential ring gear, usually a hypoid bevel gear, is secured to the differential case, which is generally produced of cast nodular or ductile iron for high torque applications. The case is secured to the ring gear and defines a chamber containing bevel pinions driveably connected to the case by pinion shaft or spider, depending on the number of bevel pinions used, a right-side bevel gear and a left-side bevel gear in continuous mes...

AI Technical Summary

Benefits of technology

[0011]This differential assembly has lower weight and rotating inertia than a differential assembly of comparable torque capacity. A forming process is applied that allows control of the case wall along the length of the side walls and work hardens the case material, provides adequate formability to produce the component, and provides a sufficiently high elastic modulus to provide good assembly stiffness. The combination of the forming process, work-hardened material properties and component design result in excellent specific stiffness, adequate strength, manufacturability and low manufacturing cost.

[0019]The differential assembly eliminates elongation of the differential pinion shaft hole in the case under repeated loading, eliminates differential pinion shaft fasteners, reduces differential case wall thickness, increases stiffness, and maximizes capacity torque in a smaller package.

Problems solved by technology

Causing material to flow in the tangential direction is difficult.

But the desired, non-uniform thicknesses are easily achieved in the longitudinal direction, where a cross section taken perpendicular to the rotational axis at any point along the length of the part is axisymmetric.

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