阅读说明：本技术 包括轮端件的车桥组件及其制造方法 (Axle assembly including wheel end pieces and method of making same ) 是由 詹姆斯·莱文森 达勒·克瓦希涅夫斯基 兰迪·霍兰德 詹姆斯·甘特 蒂莫西·曼 于 2019-07-02 设计创作，主要内容包括：一种车桥壳体组件包括车桥壳体,所述车桥壳体包括中心部分和从所述中心部分延伸的第一臂部分。所述车桥壳体组件进一步包括轮端件壳体,所述轮端件壳体包括从所述第一臂部分延伸的轮端件本体和从所述轮端件本体延伸的主轴。(An axle housing assembly includes an axle housing including a central portion and a first arm portion extending from the central portion. The axle housing assembly further includes a wheel end housing including a wheel end body extending from the first arm portion and a spindle extending from the wheel end body.)

1. A method of manufacturing an axle housing assembly, the method comprising:

providing an axle housing having a central portion and first and second arm portions extending in opposite directions from the central portion, the first arm portion including an end surface facing away from the central portion;

providing a wheel end housing, the wheel end housing comprising:

a wheel end piece body having an inboard end surface and an outboard end surface disposed opposite the inboard end surface;

a spindle having a first spindle end surface and a second spindle end surface disposed opposite the first spindle end surface, wherein the spindle is mounted to the wheel end body by joining the first spindle end surface to the outboard end surface and welding the spindle to the wheel end body; and

a mounting flange welded to the wheel end piece body and spaced apart from the main shaft; and is

Mounting the wheel end housing to the axle housing by joining the inboard end surface to the end surface and welding the wheel end housing to the axle housing, wherein the mounting flange is axially positioned closer to the axle housing than the spindle.

2. The method of claim 1, wherein the mounting flange is axially positioned closer to the axle housing than the outboard end surface.

3. The method of claim 1, wherein providing the wheel end housing further comprises mounting a suspension interface plate to a wheel end body between the inboard end surface and the outboard end surface.

4. The method of claim 1, wherein the inboard end surface is annular with a first inner diameter, the outboard end surface is annular with a second inner diameter, and the first inner diameter is greater than the second inner diameter.

5. A method of manufacturing an axle housing assembly, the method comprising:

providing an axle housing having a central portion and first and second arm portions extending in opposite directions from the central portion, the first arm portion including an end surface facing away from the central portion;

providing a wheel end housing, the wheel end housing comprising:

a wheel end body having:

an inboard end surface shaped as a ring having an outer circumferential surface;

an outboard end surface disposed opposite the inboard end surface;

a central body portion axially positioned between and spaced apart from the inboard and outboard end surfaces, the central body portion having a first cross-sectional shape that is different from a shape of the inboard end surface;

a first connecting portion extending from the inboard end surface to the central body portion; and

a second connection portion disposed opposite the first connection portion and extending from the outer end surface to the central body portion; and

a spindle having a first spindle end surface and a second spindle end surface disposed opposite the first spindle end surface, wherein the spindle is mounted to the wheel end body by joining the first spindle end surface to the outboard end surface and welding the spindle to the wheel end body; and is

The wheel end housing is mounted to the axle housing by joining the inboard end surface to the end surface and welding the wheel end housing to the axle housing.

6. The method of claim 5, wherein the outboard end surface is shaped as a ring having an outboard circumferential surface, wherein the first cross-sectional shape is different from the shape of the outboard end surface.

7. The method of claim 5, wherein the first cross-sectional shape is non-circular.

8. The method of claim 7, wherein the first cross-sectional shape is generally rectangular.

9. The method of claim 7, wherein the first cross-sectional shape extends from the first connection portion to the second connection portion.

10. The method of claim 9, wherein the wheel end piece housing further comprises a first suspension interface plate and a second suspension interface plate welded to the wheel end piece body and axially positioned between a first connection portion and the second connection portion.

11. The method of claim 5, wherein the spindle is welded to the wheel end body prior to welding the wheel end housing to the axle housing.

12. The method of claim 5, wherein the wheel end body defines a wheel end passage that is generally rectangular in the central body portion and generally circular at the inboard end surface.

13. The method of claim 12, wherein the wheel end body defines a wheel end passage that is generally rectangular in the central body portion and generally circular at the outboard end surface.

14. The method of claim 5, wherein the end surface of the first arm portion is shaped as a ring having an inner circumference and an outer circumference.

15. The method of claim 14, wherein the first arm portion further comprises an elongated portion extending from the central portion to a transition portion extending in an axial direction from the elongated portion to the end surface, wherein the elongated portion has a non-circular cross-section.

16. The method of claim 15, wherein the first arm portion defines a channel that is generally rectangular in the elongated portion and generally circular at the end surface.

17. An axle housing assembly comprising:

an axle housing, the axle housing comprising:

a central portion;

a first arm portion extending from the central portion, the first arm portion including an elongated portion extending from the central portion and a transition portion extending from the elongated portion in an axial direction, wherein the elongated portion and the transition portion cooperate to define a channel having a non-circular cross-section in the elongated portion and a circular cross-section at an end of the transition portion; and

a wheel end housing, the wheel end housing comprising:

a wheel end body extending from the first arm portion, the wheel end body including a first connection portion extending from the transition portion, a second connection portion spaced from the first connection portion, a central body portion extending from the first connection portion to the second connection portion, and a spindle extending from the second connection portion and disposed on an opposite side of the second connection portion from the central body portion, wherein the first connection portion, the central body portion, and the second connection portion cooperate to define a wheel end housing channel having a non-circular cross-section in the central body portion and a circular cross-section at an end of the first connection portion.

18. The axle housing of claim 17, wherein the wheel end piece housing passage has a circular cross-section at the end of the second attachment portion.

19. The axle housing of claim 17, further comprising a mounting flange that receives the second attachment portion and is fixedly disposed on the second attachment portion.

20. The axle housing of claim 17, further comprising a first suspension interface plate fixedly disposed on the central body portion and disposed opposite the wheel end housing channel.

Technical Field

The present disclosure relates to an axle assembly and, more particularly, to an axle assembly having an axle housing and wheel end pieces.

Background

An axle assembly is disclosed in U.S. patent application No. 9,267,596.

Disclosure of Invention

In at least one solution, a method of manufacturing an axle housing assembly is provided. The method may include providing an axle housing having a central portion and first and second arm portions extending in opposite directions from the central portion. The first arm portion may comprise an end surface facing away from the central portion. The method may further include providing a wheel end housing including a wheel end body, a spindle, and a mounting flange. The wheel end body may have an inboard end surface and an outboard end surface disposed opposite the inboard end surface. The spindle may have a first spindle end surface and a second spindle end surface disposed opposite the first spindle end surface. The spindle may be mounted to the wheel end piece body by joining a first spindle end surface to an outboard end surface and welding the spindle to the wheel end piece body. The mounting flange may be welded to the wheel end piece body and may be spaced apart from the main shaft. The method may include mounting the wheel end housing to the axle housing by joining an inboard end surface to the end surface and welding the wheel end housing to the axle housing. The mounting flange is axially positioned closer to the axle housing than the spindle.

In at least one solution, a method of manufacturing an axle housing assembly is provided. The method may include providing an axle housing having a central portion and first and second arm portions extending in opposite directions from the central portion. The first arm portion may comprise an end surface facing away from the central portion. The method may further include providing a wheel end housing comprising: a wheel end piece body having an inboard end surface and an outboard end surface disposed opposite the inboard end surface; a central body portion axially positioned between and spaced apart from inboard and outboard end surfaces; a first connecting portion extending from the inboard end surface to the central body portion; and a second connection portion that is arranged opposite to the first connection portion and extends from the outer end surface to the central body portion. The inboard end surface may be shaped as a ring having an outer circumferential surface. The central body portion may have a first cross-sectional shape that is different from the shape of the inboard end surface. The wheel end housing may further include a spindle having a first spindle end surface and a second spindle end surface disposed opposite the first spindle end surface. The spindle may be mounted to the wheel end piece body by joining a first spindle end surface to an outboard end surface and welding the spindle to the wheel end piece body. The method may further include mounting the wheel end housing to the axle housing by joining the inboard end surface to the end surface and welding the wheel end housing to the axle housing.

In at least one solution, an axle housing assembly is provided. The axle housing assembly may include an axle housing including a central portion and a first arm portion extending from the central portion. The first arm portion may include an elongated portion extending from the central portion and a transition portion extending from the elongated portion in the axial direction. The elongate portion and the transition portion may cooperate to define a channel having a non-circular cross-section in the elongate portion and a circular cross-section at an end of the transition portion. The axle housing assembly may further include a wheel end housing including a wheel end body extending from the first arm portion. The wheel end body may include a first connection portion extending from the transition portion, a second connection portion spaced from the first connection portion, a central body portion extending from the first connection portion to the second connection portion, and a spindle extending from the second connection portion and disposed on an opposite side of the second connection portion from the central body portion. The first connection portion, the central body portion, and the second connection portion may cooperate to define a wheel end piece housing channel having a non-circular cross-section in the central body portion and a circular cross-section at an end of the first connection portion.

Drawings

FIG. 1 is an exploded front elevational view of an axle assembly including an axle housing and wheel end pieces.

FIG. 2 is a perspective view of a portion of an axle housing.

Fig. 3 is a cross-sectional view taken along line 3-3 of fig. 2.

Fig. 4 is a cross-sectional view taken along line 4-4 of fig. 2.

FIG. 5 is an exploded front perspective view of the wheel end piece.

FIG. 6 is a rear perspective view of a wheel end piece including a wheel end piece body.

Fig. 7 is a side elevational view of the wheel end body of fig. 5.

Figure 8 is a top plan view of the wheel end body of figure 5.

Fig. 9 is a cross-sectional view taken along line 9-9 of fig. 6.

Fig. 10 is a cross-sectional view taken along line 10-10 of fig. 6.

FIG. 11 is a front perspective view of an axle assembly including wheel end pieces secured to an axle housing.

Detailed Description

Embodiments of the present disclosure are described herein. However, it is to be understood that the disclosed embodiments are merely exemplary and that other embodiments may take different and alternative forms. The drawings are not necessarily to scale; certain features may be exaggerated or minimized to show details of individual components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. It will be appreciated by persons skilled in the art that different features shown and described with reference to any one of the figures may be combined with features shown in one or more other figures to produce embodiments that are not explicitly shown or described. The combination of features presented provides a representative embodiment for a typical application. However, different combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations.

Referring to fig. 1 and 2, an axle housing assembly 10 may include an axle housing 12 and one or more wheel end piece housings 14. The axle housing 12 may include a center portion 22, a first arm portion 24, and a second arm portion 26. The first arm portion 24 and the second arm portion 26 may extend in opposite directions from the central portion 22. One or both of the arm portions 24, 26, or portions thereof, may be integrally formed with the central portion 22. Alternatively, the arm portions 24, 26 may be separate from the central portion 22. In this configuration, each arm portion 24, 26 may be attached to the central portion 22 in any suitable manner, such as by welding or with one or more fasteners. In at least one solution, the first arm portion 24 may extend a longer distance from the central portion 22 than the second arm portion 26. In yet another solution, the arm portions 24, 26 may have a substantially similar configuration.

In at least one solution, the arm portions 24, 26 may each have a hollow configuration such that the arm portions 24, 26 define arm channels or cavities that may receive respective axle shafts. The arm portions 24, 26 may help to isolate or isolate the internally disposed axle shafts from the surrounding environment. In at least another solution, the arm portions 24, 26 may not be hollow.

The first arm portion 24 may have an elongated portion 30 and a transition portion 32. The transition portion 32 may include an end surface 34 at an end of the first arm portion 24 opposite the central portion 22. The end surfaces 34 may face away from the central portion 22. The end surface 34 may be shaped as a ring having an inner circumference and an outer circumference. In this manner, the end surface 34 may be a generally circular end surface. The elongated portion 30 and the transition portion 32 may be disposed about a central axis 36. The transition portion 32 may extend in an axial direction (e.g., along a central axis 36) from the elongated portion 30 to the end surface 34.

Referring to fig. 3, at least a portion of the elongated portion 30 may define a non-circular cross-section about the central axis 36. The cross-section may be generally polygonal, for example (e.g., quadrilateral, which may be a parallelogram shape such as substantially rectangular, substantially square, etc.) and may define rounded inner and/or outer corners.

The cross-section of the elongated portion 30 may define an outer height H-ext₁The exterior height may extend in a first direction between exterior surfaces of the elongate portion 30 (e.g., from a bottom surface 40 to a top surface 42 of the elongate portion 30). The cross-section may define an internal height H-int₁The interior height may extend in a first direction between the inner surfaces of the elongated portion 30 (e.g., from the lower inner surface 44 to the upper inner surface 46 of the elongated portion 30). As used herein, relative terms such as "top," "bottom," "lower," "upper," and "side" refer to the relative orientations as shown in the figures.

The cross-section of the elongated portion 30 may also define an outer width W-ext₁The outer width may extend between the outer surfaces of the elongated portion 30 in a second direction that may be orthogonal to the first direction (e.g., from the first outer side surface 50 to the second outer side surface 52 of the elongated portion 30). The cross-section may define an internal width W-int₁The interior width may extend in the second direction between the interior surfaces of the elongated portion 30 (e.g., from the first side interior surface 54 to the second side interior surface 56 of the elongated portion 30).

In at least one solution, H-ext₁May be greater than W-ext₁The value of (c). H-int₁May be greater than W-int₁The value of (c). In this manner, the elongated portion 30 may have a rectangular cross-section disposed about the central axis 36.

Referring to fig. 4, the transition portion 32 may define a circular cross-section about a central axis 36. The transition portion 32 may define an outer radius R-ext in cross-section₁The outer radius may extend between the outer surfaces 60 of the transition portions 32. The cross-section may also define an inner radius R-int₁The inner radius may extend between the inner surfaces 62 of the transition portions 32.

Referring again to fig. 1, the axle housing assembly 10 may include a wheel end housing 14 disposed at a distal end of one or both of the first and second arm portions 24, 26 of the axle housing 12.

Referring to fig. 5-8, the wheel end housing 14 may include a wheel end body 70. In at least one solution, the wheel end body 70 includes a first connection portion 72. The first connection portion 72 may include an inboard end surface 74 at an inboard end of the wheel end body 70. The inboard end surface 74 may be shaped as a ring and may have an outer circumferential surface. The first connection portion 72 and the inboard end surface 74 may be disposed about a central axis 76. The center axis 76 of the wheel end housing 14 may be coaxial with the center axis 36 of the axle housing 12 when the axle housing assembly 10 is in the assembled configuration.

Referring briefly to fig. 9, the first connection portion 72 may define a circular cross-section about a central axis 76. The cross-section of the first connection portion 72 may define an outer radius R-ext₂The outer radius may extend between the outer surfaces 80 of the first connection portions 72. The cross-section may also define an inner radius R-int₂The inner radius may extend between the inner surfaces 82 of the first connection portions 72.

The wheel end piece body 70 may also include a central body portion 90. The central body portion 90 may have a cross-sectional shape referred to herein as a first cross-sectional shape. The first cross-sectional shape may be different from the shape of the inboard end surface 74. Referring briefly to fig. 11, the central body portion 90 may define a polygonal cross-section (e.g., a quadrilateral, which may be a parallelogram shape such as substantially rectangular, substantially square, etc.) about the central axis 76 of the wheel end housing 14 and may define rounded inner and/or outer corners.

The cross-section of the central body portion 90 may define an outer height H-ext₂The outer height may extend in a first direction between the outer surfaces of the central body portion 90 (e.g., from the bottom surface 100 to the top surface 102 of the central body portion 90). The cross-section may define an internal height H-int₂The interior height may extend in a first direction between the inner surfaces of the central body portion 90 (e.g., from a lower inner surface 104 to an upper inner surface 106 of the central body portion 90).

The cross-section of the central body portion 90 may also define an outer width W-ext₂The outer width may extend between the outer surfaces of the central body portion 90 in a second direction that may be orthogonal to the first direction (e.g., from the first outer side surface 110 to the second outer side surface 112 of the central body portion 90). The cross-section may define an internal width W-int₁The interior width may extend in the second direction between the interior surfaces of the central body portion 90 (e.g., from the first side interior surface 114 to the second side interior surface 116 of the central body portion 90).

One or more of the bottom surface 100, the top surface 102, the lower interior surface 104, the upper interior surface 106, the first exterior side surface 110, and the second exterior side surface 112 may be, or may include, a planar surface.

In at least one solution, H-ext₂May be greater than W-ext₂The value of (c). Furthermore, H-int₂May be greater than W-int₂The value of (c). In this manner, the central body portion 90 may have a rectangular cross-section disposed about the central axis 76.

In at least one approach, the internal height H-int of the central body portion 90₂May be at an internal height H-int of the elongated portion 30 of the first arm portion 24 of the axle housing 12₁Correspond (e.g., are equal). Further, the inner width W-int of the central body portion 90₂May be aligned with the inner width W-int of the elongated portion 30₁Correspond (e.g., are equal).

Likewise, in at least one solution, the outer height H-ext of the central body portion 90₂May be at an outer height H-ext from the elongated portion 30 of the first arm portion 24 of the axle housing 12₁Correspond (e.g., are equal). Further, the inner width W-ext of the central body portion 90₂May correspond to the inner width W-ext of the elongated portion 30₁Correspond (e.g., are equal).

The wheel end piece body 70 may also include a second connection portion 120 that may extend away from the central body portion 90.

The second connection portion 120 may include an outboard end surface 122, which may be disposed at an outboard end of the wheel end body 70 opposite the inboard end surface 74. In this manner, the second connection portion 120 may extend from the central body portion 90 to the outboard end surface 122. Further, the central body portion 90 may be axially positioned between and spaced apart from the inboard and outboard end surfaces 74, 122.

The shape of the outboard end surface 122 may be different than the shape of the first cross-sectional shape of the central body portion 90. For example, the outboard end surface 122 may be shaped as a ring having an outboard circumferential surface. The outboard end surface 122 may extend about the central axis 76. Further, the outboard end surface may have an inner diameter that is less than an inner diameter of the inboard end surface.

In this manner, the wheel end body 70 may define a wheel end channel that is generally rectangular in the central body portion 90 and generally circular at the inboard end surface 74, the outboard end surface 122, or both the inboard end surface 74 and the outboard end surface 122.

Referring again to fig. 7 and 8, the wheel end body 70 may also include one or more shoulder portions. For example, a first shoulder portion 130 may be disposed between the central body portion 90 and the inboard end surface 74, and a second shoulder portion 132 may be disposed between the central body portion 90 and the second connection portion 120. One or both of first shoulder portion 130 and second shoulder portion 132 may extend about central axis 76 (e.g., extend completely about central axis 76).

The first shoulder portion 130 may include a first shoulder surface that may extend from the central body portion 90 to a first shoulder ridge. As indicated at 138 in fig. 8, the first shoulder surface may extend at a first oblique angle from the top surface 102 of the central body portion 90. As indicated at 140 in fig. 9, the first shoulder surface may also extend at a second oblique angle from a side surface (e.g., side surface 112 or 114) of the central body portion 90. In at least one solution, the second bevel 140 may be different from the first bevel 138. For example, the first angle 138 may be in a range of about 200 degrees to about 225 degrees and the second angle 140 may be in a range of about 190 degrees to about 195 degrees.

The second shoulder surface of the second shoulder portion 132 may similarly extend from the top and side surfaces of the central body portion 90.

Referring again to fig. 5 and 6, the wheel end housing 14 can include a first suspension interface plate 150, and can further include a second suspension interface plate 152. In at least one solution, the first and second suspension interface plates 150 and 152 can be formed from the same shape. The suspension interface may include an engagement surface 160, an opposite surface 162, and one or more (e.g., two) flanges 164, which may be disposed on opposite sides of the suspension interface. A flange 164 may extend from the engagement surface 160 and may define an aperture 166. The aperture 166 may be a through-hole that may extend through the entire thickness of the flange 164 (e.g., extending from one surface of the flange to the opposite surface of the flange). In yet another solution, the aperture 166 may extend through less than the entire thickness of the flange 164.

The engagement surface 160 may be a flat surface. The opposite surface 162 may also be a flat surface and may extend parallel to the engagement surface 160. In this manner, the opposing surface 162 may receive one or more suspension components (or other suitable components) that may be secured to one or both of the suspension interfaces at the apertures 166.

In at least one solution, the suspension interface plates 150, 152 can be secured to the wheel end body 70. In one example, the suspension interface plates 150, 152 can be forged with the wheel end body 70. In another example, the suspension interface plates 150, 152 can be welded to the wheel end piece body 70. In yet another example, the suspension interface plates 150, 152 can be mechanically fastened to the wheel end body 70.

The first suspension interface plate 150 can be fastened to the wheel end body 70, for example, at the top surface 102 of the wheel end body 70, and the second suspension interface plate 152 can be welded to the wheel end body 70 at the bottom surface 100 of the wheel end body 70. In the assembled configuration shown in fig. 6, the engagement surface 160 may engage the wheel end body 70 and may be disposed opposite the wheel end housing channel. The opposite surface 162 may face away from the wheel end piece body 70, and the flange 164 may depend from the wheel end piece body 70. The first and second suspension interface plates 150, 152 can be axially positioned between the first and second connection portions 72, 120.

The wheel end housing 14 may further include a mounting flange 170. The mounting flange 170 may receive (e.g., be disposed about) the second connection portion 120 of the wheel end body 70. The mounting flange 170 may be fastened to the second connection portion 120. In one example, the mounting flange 170 may be forged with the second connection portion 120. In another example, the mounting flange 170 may be welded to the second connection portion 120. In yet another example, the mounting flange 170 may be mechanically fastened to the second connection portion 120.

The mounting flange 170 may extend away from the central axis 76. The mounting flange 170 may facilitate mounting of other components to the wheel end body 70. For example, a portion of the brake subsystem and the wheel may be mounted to the mounting flange 170. The mounting flange 170 may include a plurality of mounting stud holes, which may be arranged about the central axis 76. Each mounting stud hole may receive a respective fastener (e.g., a mounting stud).

The wheel end housing 14 may further include a spindle 180. The spindle 180 may have a first spindle end surface 182 and a second spindle end surface 184 disposed opposite the first spindle end surface 182.

The spindle 180 may be secured to the wheel end body 70 such that the first spindle end surface engages (e.g., contacts) the outboard end surface 122. In one example, the main axle 180 may be forged with the wheel end body 70. In another example, the spindle 180 may be welded (e.g., friction welded) to the wheel end body 70.

The method of manufacturing an axle housing assembly may comprise: assembling one or more components of the wheel end housing, such as fastening the main shaft to the wheel end body, fastening one or more suspension interface plates to the wheel end body, fastening the mounting flange to the wheel end body, fastening the torque plate to the wheel end body, fastening the disc brake to the wheel end body, fastening the S-cam brake to the wheel end body, or fastening another suitable component to the wheel end body.

The one-piece wheel end piece may be cast or formed as a one-piece component. The one-piece wheel end piece may be substantially free of welds between the various features. The reduction in the number of welds may reduce associated manufacturing time and/or costs. The reduced number of welds also improves the durability and reliability of the one-piece wheel end piece.

Although discussed herein as an assembly, the wheel end piece may be a unitary (e.g., cast) wheel end piece that may include a wheel end piece body (e.g., a body portion), first and second suspension interface portions, a mounting flange portion, and a main shaft portion. The body portion may define a second annular mating surface. The first suspension interface portion may be arranged at a top side of the body portion, and the second suspension interface portion may be arranged at a bottom side of the body portion opposite the top side. The mounting flange portion may be disposed opposite the second annular mating surface with respect to the first and second suspension interface portions. The main shaft portion may be arranged opposite the first and second suspension interface portions with respect to the mounting flange portion. The body portion may generally correspond to the wheel end body 70 of fig. 5-8; the first and second suspension interface portions may generally correspond to the first and second suspension interface plates; the mounting flange portion may generally correspond to the mounting flange 170; and the spindle portion may generally correspond to the spindle 180.

The method may further include mounting the wheel end housing to the axle housing by joining the inboard end surface to the end surface and welding the wheel end housing to the axle housing. In at least one solution, the spindle may be welded to the wheel end body before the wheel end housing is welded to the axle housing.

Installing one or more components contemplated herein may include welding the components. Welding may include mechanical welding (e.g., friction welding such as spin welding, linear friction welding, friction weld overlay, etc.), electric welding (e.g., induction welding), chemical welding, and the like.

During certain friction welding processes, the first and second portions may be engaged to generate heat through mechanical friction between the first and second portions. For example, an end surface of the first portion may be placed into engagement with an end surface of the second portion, thereby generating frictional heat. The frictional heating may be supplemented by non-frictional heating. For example, the first portion and/or the second portion may be heated by induction heating, resistance heating, or an external heat source.

During friction welding, a lateral force or axial load may be applied on the first portion and/or the second portion to plastically displace and fuse the first portion and the second portion together. A lateral force or axial load may push the first portion toward the second portion and vice versa. A lateral force or axial load may produce one or more beads on the first and second portions. In another solution, no curling may occur.

The axle housing assembly 10 may include one or more of the components discussed herein and may be formed by one or more of the steps discussed herein. For example, the axle housing assembly 10 may include an axle housing 12 including a center portion 22 and a first arm portion 24 extending from the center portion 22. The first arm portion 24 may include an elongated portion 30 that may extend from the central portion 22 and a transition portion 32 that extends from the elongated portion 30 in an axial direction. The elongate portion 30 and the transition portion 32 may cooperate to define a channel having a non-circular cross-section in the elongate portion 30 and a circular cross-section at the end of the transition portion 32. The axle housing assembly 10 may include a wheel end housing 14 including a wheel end body 70 extending from the first arm portion 24. The wheel end body 70 may include a first connection portion 72 extending from the transition portion 32, a second connection portion 120 spaced apart from the first connection portion 72, and a central body portion 90 extending from the first connection portion 72 to the second connection portion 120. The wheel end body 70 may further include a spindle 180 extending from the second connection portion 120 and may be disposed on an opposite side of the second connection portion 120 from the central body portion 90. The first connection portion 72, the central body portion 90, and the second connection portion 120 may cooperate to define a wheel end piece housing channel having a non-circular cross-section in the central body portion 90 and a circular cross-section at the end of the first connection portion 72. The axle housing assembly 10 may further include a mounting flange 170 that receives the second attachment portion 120 and is fixedly disposed on the second attachment portion 120. The mounting flange 170 may be axially located closer to the axle housing 12 than the main shaft 180. Further, the mounting flange 170 may be axially positioned closer to the axle housing 12 than the outboard end surface of the wheel end body.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, features of a number of different embodiments may be combined to form further embodiments of the invention that may not be explicitly set forth or illustrated. While various embodiments may have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to a desired feature or features, those of ordinary skill in the art will recognize that compromises may be made in one or more features or characteristics depending on the particular application and overall system attributes desired for the implementation. These attributes may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, and the like. As such, embodiments that are stated as being less desirable with respect to one or more features than other embodiments or prior art implementations do not fall outside the scope of the present disclosure and may be desirable for particular applications.