The invention discloses an integral forming method of a weldless axle housing of a heavy
truck. According to the method, reversed
central spindle necking is carried out on two sides of the axle
housing first, then hydro-bugling is carried out on the middle of the axle housing to obtain a bulging tube blank with sizes of two sides of the axis different, and then
necking is carried out on two ends of the axle housing to obtain a preformed tube blank; ends of the preformed tube blank are sealed by a left pressure head and a right pressure head of a die and liquid is filled in the axle housing on a four-way hydraulic
machine, integral press-forming is carried out on the preformed tube blank from the upper side, the lower side, the front side and the back side through an upper module, a lower module, a front module and a back module to obtain an axle housing tube fitting, a hemispherical rear oil cap is arranged on the rear side of an axle
package part, and the front side of the axle
package part is a plane; a round hole is punched in the front side of the axle
package, the rear oil cap is reshaped with a
stamping die, and then an axle housing workpiece is obtained. The heavy
truck axle housing manufactured with the method is weldless, high in strength and rigidity, high in shape accuracy, good in wall thickness distribution, and low in manufacturing cost. Compared with a traditional hydro-bugling technique, the method has the advantages that
liquid pressure needed in a manufacturing process is reduced by more than 60% and the
tonnage of forming equipment is reduced by more than 50%.