Cost-reduced torque converter shrouds

Abstract

A method of manufacturing an annular transmission component for a vehicle includes providing a tube defining an annular wall having a predetermined diameter. The tube is cut to a form a tube blank having a first end and a second end. The tube blank placed into a forming machine and the first end of the tube blank is rolled relative to the second end of the tube blank forming an annular U-shaped channel defined between the first and the second end.

1 - 14 . (canceled) 
     
     
         15 . A method of making an annular transmission component for a vehicle, the method comprising:
 placing a tube blank having first and second ends into a forming machine; and   rolling the first end of the tube blank radially and axially relative to the second end thereby forming an annular, arcuate shaped channel between the first end and the second end.   
     
     
         16 . The method of  claim 15 , wherein rolling the first end of the tube blank includes rolling the first end radially outward. 
     
     
         17 . The method of  claim 15 , wherein rolling the first end of the tube blank includes rolling the first end radially inward. 
     
     
         18 . The method of  claim 15 , wherein the forming machine comprises at least one of a roll former, a die press, and an orbit forming machine. 
     
     
         19 . The method of  claim 15 , wherein the tube blank comprises at least one of a high strength steel, a high-carbon steel, HSLA steel, or a high strength composite. 
     
     
         20 . The method of  claim 15 , wherein after the rolling the first end has a first circumference and the second end has a second, different circumference. 
     
     
         21 . The method of  claim 20 , wherein a difference between the first circumference and the second circumference corresponds to a length of the tube blank between the first end and the second end. 
     
     
         22 . The method of  claim 21 , comprising selecting the tube blank to have the length between the first end and the second end for forming the U-shaped channel with a desired surface length between the first end and the second end and the difference between the first circumference and the second circumference. 
     
     
         23 . The method of  claim 15 , comprising using the forming machine for establishing notches along an edge at the first end or the second end. 
     
     
         24 . The method of  claim 15 , comprising using the forming machine for establishing slots in a wall of the arcuate shaped channel. 
     
     
         23 . The method of  claim 15 , wherein the tube blank includes a seam extending axially along the tube blank between the first end and the second end. 
     
     
         24 . The method of  claim 23 , comprising establishing the seam by at least one of welding edges of material of the tube, mechanically interlocking the edges of the material of the tube, and gluing the edges of material of the tube. 
     
     
         25 . The method of  claim 15 , wherein
 the tube blank has a metal grain having an alignment with an axial direction from the first end to the second end; and   rolling the first end comprises maintaining the alignment of the metal grain from the first end to the second end.   
     
     
         26 . The method of  claim 15 , wherein the first end and the second end have an initial diameter and the method comprises
 supporting the second end in the forming machine to maintain the initial diameter of the second end during the rolling; and   changing the diameter of the first end during the rolling.   
     
     
         27 . The method of  claim 15 , wherein rolling the first end comprises moving the first end into a position relative to the second end where the first end and the second end are in a single plane and the arcuate channel is a U-shaped channel. 
     
     
         28 . The method of  claim 15 , wherein rolling the first end comprises moving the first end into a position relative to the second end where the first end and the second end are in separate planes and the arcuate channel is a J-shaped channel. 
     
     
         29 . The method of  claim 15 , wherein the rolling is accomplished during a single movement of a die member of the forming machine. 
     
     
         30 . A method of making an annular shroud, the method comprising:
 situating a tube in a forming machine, the tube having a first end, a second end and an annular wall of a generally constant initial diameter between the first end and the second end;   roll forming the tube to cause the first end of the tube to have a different diameter than the initial diameter and to shape the annular wall to have an arcuate shape between the first end and the second end; and   supporting the second end in the forming machine to maintain the initial diameter near the second end.   
     
     
         31 . The method of  claim 30 , wherein roll forming the tube comprises rolling the first end radially and axially relative to the second end. 
     
     
         32 . The method of  claim 30 , wherein the roll forming is accomplished during a single movement of a die member of the forming machine. 
     
     
         33 . The method of  claim 30 , wherein
 the tube has a metal grain having an alignment with an axial direction from the first end to the second end; and   the roll forming comprises maintaining the alignment of the metal grain from the first end to the second end.   
     
     
         34 . The method of  claim 30 , wherein the different diameter of the first end is larger than the initial diameter.