Differential Cases

NETFORM has developed a cost-effective solution for lightweight differential cases.

Several design options exist to allow the manufacture of a variety of differential types.

In addition, clutch packs can be incorporated into the differential as required at minimal additional cost.

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Flowforming is a cold rotary forming process where a rotating metal preform is formed over a tool by (typically) three rollers.

The rollers deform the preform, forcing it against the tool (also known as a mandrel), axially lengthening and radially thinning the material.

The material will take on the reverse profile of the mandrel, allowing the forming of features such as splines and piston seal surfaces.

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The very nature of the cold forming process requires material with highly formable properties.  These properties do not lend themselves easily to machining.  Chip management is particularly challenging due to the machined material not wanting to break during machining.

In addition, the nature of cold forming requires that excess material over the finished components is minimized.  This result in very small depths of cut during machining.

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