Axle Housings & Assemblies
Our proprietary cold extrusion process increases the strength of the base material and produces housings that are stronger and lighter weight than what is currently available with traditional manufacturing methods. We start with material that has a yield strength of 50-55 KSI and based on the amount of reduction the material strength can be increased to over 100 KSI. Our VARI-LITE® process utilizes a unique extrusion process that yields a tube that incorporates a variable wall. This allows us to provide thicker walls for the load bearing or weld areas and thinner wall sections for the non-stressed areas of the tube.
We have also developed a variable wall tube that incorporates an oval I.D. This will reduce the material cost and provide greater weight savings by having the thicker wall sections at the top and bottom of the tube where there is greater stress and reduce the wall thickness at the neutral axis of the tube where the additional strength is not required. U.S. Manufacturing utilizes two warm forming technologies to produce spindles for full float applications. The two hit process provides additional strength as the first hit is done in a cold form process. The temperature of the spindle is then increased for the 2nd hit which provides additional formability. This process allows us to increase the material properties from 50-55 KSI to a range of 100-110 KSI in the bearing and seal area of the spindle. For applications with reduced load requirements we provide spindles utilizing our one hit warm form process. This reduces costs by utilizing less expensive raw materials, and eliminating the cold form, while still providing a spindle with a yield strength of 70-80 KSI. In order to fully support our customers, we use analytical tools that allow us to model and design the optimum tube to meet your specific performance requirements. The producibility and design is fully validated with complete in-house testing and process intent prototype manufacturing capabilities. U.S. Manufacturing is also a leader in welding, utilizing inertia and friction welding for joining the tube & spindles. MIG and Projection welding processes are utilized for the many brackets that are required for the completed tube assemblies. Following 3D parametric modeling, we can establish a best fit condition for the manufacturing process, and by selecting from a variety of welding equipment can assure the most cost effective and high quality manufacturing process for these assemblies. With over 43 years of machining experience, we provide completely machined assemblies including induction hardening of the spindle bearing surface when required. U.S. Manufacturing designs and builds complete manufacturing cells to provide dedicated production that assures quality and the most cost effective manufacturing operations for the axle housing assemblies. |