Axel assembly

Abstract

An axle assembly having a wheel flange with a central opening and a slot having an end dimensioned to fit within the wheel flange central opening. A molten binder, such as molten zinc, fills the space in between the wheel central opening and the shaft end. Upon cooling, the binder locks the wheel flange and shaft together.

I claim: 
     
         1 . A method for constructing an axle assembly comprising the steps of:
 forming a wheel flange with a central opening,   machining an elongated shaft so that one end of the shaft has a smaller cross sectional shape than said central opening of said wheel flange,   positioning said one end of said shaft into said wheel flange central opening,   filing a space between said one end of said shaft and said wheel flange with a molten binder which, upon setting, mechanically locks said shaft and said wheel flange together.   
     
     
         2 . The method as defined in  claim 1  wherein said forming step comprises the step of forming said wheel flange from powdered metal. 
     
     
         3 . The method as defined in  claim 1  wherein said machining step comprises the step of forming knurls on said one end of said shaft. 
     
     
         4 . The method as defined in  claim 1  further comprising the step of heat treating said wheel flange. 
     
     
         5 . The method as defined in  claim 1  further comprising the step of heat treating said elongated shaft. 
     
     
         6 . The method as defined in  claim 5  further comprising the step of grinding said elongated shaft following the step of heat treating. 
     
     
         7 . The method as defined in  claim 1  wherein said molten binder comprises molten metal having zinc as one component. 
     
     
         8 . The method as defined in  claim 1  wherein said wheel flange has at least one through hole spaced radially outwardly from said wheel flange central opening and wherein said filling step comprises the step of filling said at least one through hole. 
     
     
         9 . The method as defined in  claim 3  wherein said filling step comprises the step of filling said knurls. 
     
     
         10 . The method as defined in  claim 1  wherein said wheel flange has a plurality of cutouts formed around said central opening and wherein said filling step comprises the step of filling said plurality of cutouts. 
     
     
         11 . A method for constructing an axle assembly comprising the steps of:
 forming a wheel flange with a central opening, said wheel flange including a plurality of circumferentially spaced cutouts,   machining an elongated shaft so that one end of the shaft has a smaller cross sectional shape than said central opening of said wheel flange,   positioning said one end of said shaft into said wheel flange central opening,   filing a space between said one end of said shaft and said wheel flange with a molten binder which, upon setting, mechanically locks said shaft and said wheel flange together.   
     
     
         12 . The method as defined in  claim 11  wherein said filling step comprises the step of filling said plurality of cutouts. 
     
     
         13 . A method for constructing an axle assembly comprising the steps of:
 forming a wheel flange with a central opening, said wheel flange including a plurality of circumferentially spaced cutouts,   machining an elongated shaft so that one end of the shaft has a smaller cross sectional shape than said central opening of said wheel flange, said elongated shaft including knurls formed on said one end of the elongated shaft,   positioning said one end of said shaft into said wheel flange central opening,   filing a space between said one end of said shaft and said wheel flange with a molten binder which, upon setting, mechanically locks said shaft and said wheel flange together.   
     
     
         14 . The method as defined in  claim 13  wherein said filling step comprises the step of filling said knurls. 
     
     
         15 . The method as defined in  claim 13  wherein said filling step comprises the step of filling said plurality of cutouts.