Wheel bearing assembly comprising a joint and corresponding method of manufacture

Abstract

The present invention resides in a wheel bearing assembly ( 100 ) comprising a flanged hub ( 110 ) and at least one second component ( 130 ) that is joined to the flanged hub by means of a radially intermediate joint ( 160 ). Specifically, the flanged hub has a first joining surface and the second component has a second joining surface, radially opposite from the first joining surface and spaced therefrom, such that a groove is defined between the first and second joining surfaces. According to the invention, the radially intermediate joint ( 160 ) is formed by an insert ring made from a high strength material that is pressed into the groove. The invention also relates to a corresponding method of manufacturing a wheel bearing unit.

1 . A wheel bearing assembly comprising a flanged hub and at least one second component joined to the flanged hub, and
 the flanged hub having a first joining surface;   the second component having a second joining surface, radially opposite from the first joining surface and spaced therefrom, such that a groove is defined between the first and second joining surfaces; and wherein   the flanged hub and the second component are joined by means of an insert ring that is pressed into the groove.   
     
     
         2 . The assembly according to  claim 1 , wherein one of the first and second joining surfaces comprises a convex portion and the other of the first and second joining surfaces comprises a concave portion, such that the groove comprises an arcuate section. 
     
     
         3 . The assembly according to  claim 1 , wherein the first and second joining surfaces comprise a cylindrical surface at an entrance side of the groove, such that the groove comprises a cylindrical section. 
     
     
         4 . The assembly according to  claim 2 , wherein the insert ring has a volume that is at least equal to a volume of the arcuate section, and has a thickness (t) that is equal to a maximum radial gap between the convex and concave portions. 
     
     
         5 . The assembly according to  claim 2 , wherein the convex portion has an apex with a diameter that is equal to a maximum diameter of the joining surface which comprises the concave portion. 
     
     
         6 . The assembly according to  claim 1 , wherein the at least one second component is a separate inner ring 
     
     
         7 . The assembly according to  claim 6 , wherein a nose part of the flanged hub is provided with face splines. 
     
     
         8 . The assembly according to  claim 7 , wherein the nose part is hardened. 
     
     
         9 . The assembly according to  claim 6 , wherein an inboard side face of the separate inner ring is provided with face splines. 
     
     
         10 . The assembly according to  claim 9 , wherein the splines on the separate inner ring and the splines on the nose part are in alignment. 
     
     
         11 . The assembly according to  claim 1 , wherein the groove and the insert ring have a non-circular cross-section for enabling torque transfer. 
     
     
         12 . The assembly according to  claim 1 , wherein the insert ring is provided with torque transfer means, formed by a trailing edge of the insert ring that is radially deformed such that a first portion extends between adjacent splines on the separate inner ring and a second portion extends between adjacent splines on the nose part. 
     
     
         13 . The assembly according to  claim 1 , wherein the insert ring comprises a radially outward extension and a radially inward extension, and one of the first and second joining surfaces comprises a recess for receiving the radially outward extension and the other of the first and second joining surfaces comprises a recess for receiving the radially inward extension. 
     
     
         14 . The assembly according to  claim 13 , wherein the insert ring is formed from two or more sections, each of which comprises a radially inward extension and a radially outward extension. 
     
     
         15 . The assembly according to  claim 1 , wherein the at least one second component is a constant velocity joint. 
     
     
         16 . The assembly according to  claim 1 , wherein the at least one second component is a locking ring for retaining one or more bearing inner rings on the flanged hub. 
     
     
         17 . The assembly according to  claim 1 , wherein at least a third component is joined to the flanged hub by means of an insert ring pressed into a gap between radially opposite joining surfaces. 
     
     
         18 . The assembly according to  claim 1 , wherein the insert ring is made of a material with a yield strength of 250-1200 MPa. 
     
     
         19 . A method of manufacturing a wheel bearing unit comprising a flanged inner ring and a separate inner ring, the method comprising steps of:
 providing a concave joining surface on one of the flanged inner ring and the separate inner ring;   providing a convex joining surface on the other of the flanged inner ring and the separate inner ring;   arranging the separate inner ring coaxially around the flanged inner ring, such that the convex and concave joining surfaces are radially opposite each other and a gap is formed therebetween;   pressing an insert ring into the gap, such that the insert ring is deformed to fill the gap, adopt its shape and form a joint between the flanged inner ring and the separate inner ring.   
     
     
         20 . The method according to  claim 19 , wherein the step of arranging comprises pressing the separate inner ring against an inboard row of rolling elements, such that bearing preload is set by means of the joint formed. 
     
     
         21 . The method according to  claim 19 , further comprising a step of hardening a nose part of the flanged hub. 
     
     
         22 . The method according to  claim 21 , further comprising a step of providing a first set of face splines on the nose part. 
     
     
         23 . The method according to  claim 22 , further comprising a step of providing a second set of face splines on an inboard side face of the separate inner ring, aligned with the first set of splines. 
     
     
         24 . The method according to  claim 23 , wherein the step of pressing comprises radially deforming a trailing edge of the insert ring such that a first portion thereof extends between adjacent splines on the separate inner ring and second portion extends between adjacent splines on the flanged hub. 
     
     
         25 . The method according to  claim 23 , wherein the steps of providing the first and second set of face splines are performed in a single machining operation, wherein the trailing edge of the insert ring is simultaneously machined to form part of the splines.