Importance

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Abstract

A method for forming an enlarged diameter aluminum alloy driveshaft tube having an interior reduced diameter portion that avoids clearance issues with respect to other components of the vehicle includes the initial step of providing a tube of aluminum alloy material having a diameter that corresponds to the enlarged diameter of the driveshaft tube to be formed. Then, a determination is made as to whether any component of the vehicle is located sufficiently close to the driveshaft tube to interfere with the rotation thereof during normal operation. If so, the position and axial length of the potential interference is located on the aluminum alloy tube. A diameter reducing process is then performed on the aluminum alloy tube to form the interior reduced diameter portion to eliminate the potential interference. Next, the ends of the enlarged diameter tube may be reduced if desired, such as by swaging, to form the driveshaft tube having the first and second diameter reducing portions at the ends thereof If desired, the step of forming the first and second diameter reducing portions can precede or occur simultaneously with the step of forming the interior reduced diameter portion. To complete the method of this invention, yokes are secured to the reduced diameter end portions of the driveshaft tube, and the driveshaft tube is installed in the drive train system of the vehicle.

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First Claim