Knuckle hub assembly and method for making same

Abstract

A knuckle hub assembly (10) and a method for manufacturing same whereby brake run out is produced includes a knuckle (12), a bearing (28) press fit into the knuckle (12), and a wheel hub (14) coupled to the bearing (28) and rotateable with respect to the knuckle (12). The wheel hub (14) has a flange surface (34) having a relief channel (60) formed therein. A plurality of wheel studs (44) are press fit into bolt opening (42) formed in the relief channel (60). This arrangement provides a flat flange surface (34) for mating with a rotor (42) to minimize brake run out. The knuckle hub assembly (10) is mounted into a floating tool for finish turning of the flange surface (34) to provide minimal run out and maximum flatness.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present μm micrometers (or microns) or better. Additionally, the run-out is minimized to 14 μm micrometers (or microns) or better and the co-planarness of the inner and outer surfaces 62, 64 is 20 μm micrometers or better. However, the flatness requirements may be varied. A person having ordinary skill in the art will appreciate that as used herein the terms “or better” mean less than or having a flatness better than the mentioned amount. For example, a flatness of 15 microns is a flatness better than and less than 20 microns.

FIGS. 7 through 12 illustrate a preferred part clamping fixture 70 in accordance with the present invention. The part clamping fixture 70 is preferably incorporated into a lathe machine (not shown) and is used to locate and hold the knuckle/hub assembly 10 for refinishing, in accordance with the process described above.

As shown in FIG. 7, the part clamping fixture 70 includes a generally flat top surface 72 for abutting a portion or surface of the lathe machine. The generally flat top surface 72 includes an opening 74 formed therein in which a split collar 76 is generally positioned for engagement with a drive motor from the lathe. The split collar 76 is disposed such that it is rotatable with respect to the opening 74. The split collar 76 has a top surface 78 with a plurality of drive motor engagement notches 80 that communicate with the drive motor from the lathe in order to rotate the split collar 76.

With reference to FIGS. 7 through 12, the part clamping fixture 70 is shown in more detail. The fixture 70 includes a plurality of keys 82 that fit into recesses 84 formed in the generally flat top surface 72. The keys 82 have fasteners 86 that pass through both the keys 82 and the generally flat top surface 72 to secure the keys 82 to a spacer plate 88. The spacer plate 88 is disposed on top of a base plate 90 with the two plates 88, 90 being secured by standard fasteners 92 that extend through the generally flat top surface 72.

The split collar 76 has a bore 94 formed therein in which a toothed gear 96 is disposed. The toothed gear 96 is secured to a puller member 98 that, when lowered by the lathe, extends generally downward and into communication with the knuckle 12. The toothed gear 96 is rotatable with respect to the split collar 76 and is supported at a bottom surface 100 by a u-joint adapter 102 that has a central opening 104 formed therein that encompasses the puller member 98.

The part clamping fixture 70 has a right housing portion 106, a right cover portion 108, and a right pull piston 110 disposed in the right housing portion 106. The part clamping fixture 70 also includes a left housing portion 114, a left cover 116, and a left pull piston 118 disposed within the left housing portion 114. Both the right pull piston 110 and the left pull piston 118 are secured to the base plate 90 by respective fasteners 112, 120. Each of the right housing portion 106 and the left housing portion 114 are moveable with respect to the respective pull pistons 110, 118 such that respective chambers 122, 124 are formed between each housing portion 106, 114. Each chamber 122, 124 has an orifice 126, 128 in fluid communication therewith allowing fluid to enter and exit the respective chamber 122, 124 to assist in moving the right and left housing portions 106, 114 upwardly and downwardly. The left and right chambers 122, 124 are sealed from their respective housings 106, 114 by a plurality of o-rings 130. Obviously any other sealing mechanism may alternatively be utilized. The left pull piston 118 is preferably smaller in length and diameter than the right pull piston 110 to ensure that equal forces are applied to the knuckle 12. It should be understood that the size of the pull pistons 110 and 118 may vary depending upon the knuckle configuration.

As shown in FIG. 9, a bayonet 132 is preferably inserted into the spline 40 defined by the inner surface 38 of the wheel pilot portion 36 of the flange portion 32. The bayonet 132 is for engagement with the puller member 98 to lift the knuckle/hub assembly 10, as described in more detail below. The bayonet 132 preferably engages a washer bore or face 133 in order to lift the assembly 10.

As shown in FIG. 11, the right housing portion 106 is retained in proximity with the base plate 90 by a pair of retaining blocks 134. Each of the retaining blocks 134 has a supporting portion 136 that engages a flange portion 138 of the right housing portion 106. Each of the retaining blocks 134 is secured to the base plate 90 by a fastener 140 or the like. A pair of guide pins 142 are disposed in the right housing portion 106. Each of the guide pins 142 is secured to the base plate 90 at an upper end 144 and each is in communication with a spring 146 at a lower end 148. Each spring 146 fits within a recess 150 formed in the lower end 144 of each of the guide pins 142 and extends downwardly into contact with the right housing portion 106. The biasing force from the springs 146 helps bias the right housing portion 106 away from the guide pins 142.

As also shown in FIG. 11, the right housing portion 106 includes a pair of bores 152 within which a respective piston 154 reciprocates. Each piston 154 moves between a normally unengaged position and a knuckle engaging position. The bores 152 are each sealed adjacent the outer ends 156 of the pistons 154 by an end cap 158. The inner ends 160 of each of the pistons 154 has a gripper portion 162 and a swiveling gripper portion 164 which allow the piston 154 to engage and hold the upper strut arm 155 of the knuckle 12 when the piston 154 is in the knuckle engaging position. Each piston 154 reciprocates within a bushing 166 secured within the respective bore 152 to ensure proper alignment of the gripper portions 162 and the swiveling gripper portions 164 with respect to the upper strut arm 155.

Turning now to FIG. 12, which is a cross-sectional view of the fixture assembly 70 through the left housing portion 114. The left housing portion 114 is also retained in proximity with the base plate 90 by a pair of retaining blocks 168. Each of the retaining blocks 168 has a supporting portion 170 that engages a flange portion 171 of the left housing portion 114. Each of the retaining blocks 168 is secured to the base plate 90 by a fastener 172 or other securing means. A pair of guide pins 174 are disposed in the left housing portion 114. Each of the guide pins 174 is secured to the base plate 90 at an upper end 176 and each is in communication with a spring 178 at a lower end 180 of the guide pins 174. Each spring 178 fits within a recess 182 formed in the lower end 180 and extends downwardly into contact with the left housing portion 114. The biasing force from the springs 178 helps bias the left housing portion 114 away from the guide pins 174. The left guide pins 174 are preferably smaller in length and diameter than the right guide pins 142.

As also shown in FIG. 12, the left housing portion 114 includes a pair of bores 184 within which a respective piston 186 reciprocates. Each piston 186 moves between a normally unengaged position and a knuckle engaging position. The bores 184 are each sealed adjacent the outer ends 188 of the pistons 186 by a respective end cap 190. The inner ends 182 of each of the pistons 186 have a gripper portion 194 and a swiveling gripper portion 196 which allow the pistons 186 to engage and clamp the lower ball joint 198 of the knuckle 12 when the pistons 186 are in a knuckle engaging position. Each piston 186 reciprocates within a busing 188 secured within each bore 184 to ensure proper alignment of the gripper portion 194 and the swiveling gripper portion 196 with respect to the lower ball joint 198.

Referring now to FIGS. 9 and 10, which illustrate the puller member 98 and the surrounding encasing 200. The puller member 98 has a head portion 202 around which the toothed gear 96 is located, a neck portion 204 which passes through the opening 104 in the u-joint adapter 102, and a stem portion 206 which is rotatable within a bore 208 formed in the surrounding encasing 200. The surrounding encasing 200 has a plurality of bearings 210 disposed around the bore 208 to assist in the rotation of the stem portion 206.

The encasing 200 includes an upper body portion 212 that has an upper end cap portion 214 disposed thereabove, a lower end cap portion 216 disposed therebelow, and a spacer portion 218 disposed between the upper body portion 212 and the lower end cap portion 216. The components of the upper body portion 212 are held together by a fastener 220 or other securing mechanism. The encasing 200 also includes a lower stop portion 222 which is secured to an upper end cap 224 by a fastener 226 or other securing mechanism. The upper body portion 212 and the lower stop portion 222 are surrounded by a body portion 228 having a stop portion 230 secured thereto. The encasing 200 is preferably secured to the underside of the base plate 90 by a plurality of fasteners 232, such as bolts or other securing mechanisms.

An upper reservoir 234 is preferably formed in the upper body portion 212. The upper reservoir 234 is in fluid communication with a fluid inlet port 236 for receiving hydraulic fluid therein. The upper reservoir 234 is also in fluid communication with a first fluid orifice 238 formed in the stem portion 206 of the puller member 98. The first fluid orifice 238 is in fluid communication with an internal fluid passageway 240 which is in fluid communication with a second fluid orifice 242 formed in the stem portion 206. Fluid that passes through the second fluid orifice 242 is passed into a lower reservoir 244. The lower reservoir 244 is formed between the lower stop portion 222 and the upper end cap 224.

The stem portion 206 has an annular flange 246 integrally formed thereon. The annular flange 246 is preferably disposed in the lower reservoir 244. The annular flange 246 and the upper end cap 224 are in mechanical communication through the inclusion of a plurality of springs 248 disposed in recesses 250, 252 formed in their respective surfaces and a spring drive pin 254. Thus, as hydraulic fluid enters the lower reservoir 244 through the second fluid orifice 242, the annular flange 246 is caused to move upward against the force of the springs 248.

In operation, a knuckle/hub assembly 10 which is to be refinished in accordance with the process, as described in detail above, is located in the lathe and generally beneath the part clamping fixture 70. The knuckle/hub assembly 10 is preferably resting on a pallet or other supporting structure with unobstructed passages. After the knuckle/hub assembly 10 has been located on the pallet beneath the part clamping fixture 70, the bayonet 132 enters the spline 40 of the assembly 10 by passing up through the pallet upon which the assembly 10 is resting. The bayonet 132 is pressed upward until a shoulder portion 256 contacts the washer face 133 of the flange portion 32 forcing it upward. The assembly 10 is lifted by the bayonet 132 at least enough so that the wheel studs 44 are clear from the pallet 10.

Thereafter, the lathe lowers the puller member 98 and the puller encasing 200 through the opening 74 and into communication with the knuckle 12. The stem portion 206 of the puller member 98 has a recess 258 formed at its lower end 260 which is opposite the head portion 202. The recess 258 is non-uniform in diameter as in one orientation, it is large enough to receive a rounded top portion 260 of the bayonet 132 therewithin. However, when the stem portion 206 is rotated 90 degrees, its diameter is not large enough to receive the rounded top portion 260 therewithin or to allow the rounded top portion 260 to be withdrawn from the recess 258 if it is positioned therein. Thus, when the puller member 98 is lowered, it is oriented so as to receive the rounded top portion 260 therewithin.

After the puller member 98 and the puller encasing 200 have been lowered, the pair of right pistons 154 and the pair of left pistons 186 are hydraulically actuated in order to apply a pinching or clamping force to the knuckle 12. The right pistons 156 apply a clamping force to the opposing sides of the upper strut arm 155 through the use of the gripper portions 162 and the swiveling gripper portions 164. Similarly, the left pistons 186 apply a clamping force to the opposing sides of the lower ball joint 198 through the use of the gripper portions 192 and the swiveling gripper portions 196. The lifting of the assembly 10 by the bayonet 132 and the lowering of the puller member 98 forces the knuckle 12 into contact with the stop portion 230. The stop portion 230 has an annular shoulder 262 which engages knuckle 12. These actions locate the knuckle/hub assembly 10 within the lathe and also fix the knuckle 12 to the lathe separately from any drive mechanism. Further, the knuckle 12 acted on by the pullers and grippers so that the knuckle is fixed and located. The knuckle 12 is not exposed to any bearing pre-load force.

After the assembly 10 is located, the bayonet 132 is engaged by rotating the puller member 98 and the puller encasing 200 with respect to the surrounding body portion 228. The puller member 98 and the puller encasing 200 are free to rotate with respect to the body portion 228 and are rotated 90° in order to engage the bayonet 132. Thereafter, a clamping force is introduced by applying pressure to the annular flange 236 by introducing hydraulic fluid into the lower reservoir 244 through the second fluid orifice 242 forcing the puller 20 upward. By pulling the puller member 98 up, the bayonet 132 is also pulled upward such that the lower stop portion 222 sits on the inner race 31 of the bearing 28 in order to apply a force thereto and thus preload the bearing 28.

After the assembly 10 has been located and clamped as described above, the final finishing process of the inner and outer surfaces 62, 64 of the hub flange face 34 can be performed by a finishing tool. In such a process, the hub 14 is driven such that it is rotating with respect to the knuckle 12 in which is fixed. The finishing tool is also preferably single tool such as a CNC tool, as is well known in the art. However, a variety of the other finishing tools may alternatively be utilized.

One of the features of the fixture assembly 70 is to turn the wheel hub 14 and the bearing 28 compliantly, such that the stem portion 206 and the annular flange 246 are free to float and follow the knuckle/hub bearing's axis of rotation. It is further preferred that the flange surface 34 is probed before final finishing to ensure a small final finish cut, i.e., decreasing the amount of material removal that is required during the final finish cut. This helps control the distance between the caliper ears and the flange face 34.

Other objects and features of the present invention will become apparent when reviewed in light of detailed description of the preferred embodiment when taken in conjunction with the attached drawings and appended claims.

Claims

1. A wheel end assembly for a motor vehicle, comprising:

a knuckle having a generally circular bore therein;

a bearing having an inner race and an outer race, said bearing in communication with said knuckle;

a wheel hub having a neck portion, in rotational communication with said bearing, and a flange portion attached to said neck portion;

said flange portion having a flange face with an outer portion, an inner portion, and a relief channel disposed between said outer portion and said inner portion;

a plurality of wheel bolt receiving apertures formed in said relief channel each for receipt of a wheel bolt therethrough;

said inner portion and said outer portion of said flange face lying generally in a single plane with said plane being generally parallel to a plane in which a pair of brake mounting structures are disposed;

wherein run-out of said flange face with respect to an axis of rotation of said bearing and said knuckle is minimized, and wherein said inner portion of said flange face and said outer portion of said flange face have a flatness of at least 20 14 μm or less; and

wherein said inner portion of said flange face and said outer portion of said flange faces have a flatness of 20 μm or less.

2. The assembly as recited in claim 1, further comprising:

a knuckle having a plurality of apertures formed therein in said knuckle for attachment of said knuckle to the vehicle, said knuckle having a generally circular bore formed therein.

3. The assembly as recited in claim 2, wherein said generally circular bore of said knuckle has includes an upper snap ring groove and a lower shoulder portion for receiving said bearing therebetween.

4. The assembly as recited in claim 3, wherein a snap ring is positioned in said snap ring groove and wherein said bearing is snap fit into said knuckle between said snap ring and said lower shoulder portion.

5. The assembly as recited in claim 1, wherein said neck portion of said wheel hub is press fit into communication with said bearing.

6. The assembly as recited in claim 1, wherein said bearing outer race is integrally formed with a said knuckle.

7. The assembly as recited in claim 1, wherein said bearing inner race is integrally formed with said neck portion of said wheel hub.

8. The assembly as recited in claim 1, wherein parallelism between said inner portion of said flange face and said outer portion of said flange face and a pair of brake caliper ears can be accurately maintained.

9. A hub assembly comprising:

a knuckle;

a bearing structure that is intended to communicate in communication with a said knuckle;

a wheel hub having a neck portion and a flange portion, said neck portion being in rotatable communication with said bearing, said wheel hub being in rotatable communication about an axis of rotation with respect to said knuckle;

a flange face formed on said flange portion for mating with a brake rotor;

a relief channel formed in said flange face and dividing said flange face into an inner portion and an outer portion; and

whereby wherein said flange face inner portion is parallel to a first brake caliper and said flange face outer portion is parallel to a second brake caliper and whereby wherein lateral run-out of said flange face portions with respect to said brake rotor axis of rotation of said bearing and said brake rotor is minimized to 20 14 μm or better or less.

10. The assembly as recited in claim 9, wherein said inner portion and said outer portion of said flange face are generally co-planar to each other.

11. The assembly as recited in claim 10, wherein a plurality of wheel bolt receiving apertures are formed in said relief channel, each of said apertures receiving a wheel bolt therethrough.

12. The assembly as recited in claim 11, wherein said supporting structure is part of a motor vehicle.

13. The assembly as recited in claim 10, wherein said bearing is intended to be received in a generally circular bore formed in said knuckle.

14. The assembly as recited in claim 13, wherein said generally circular bore receives said bearing therein and wherein said attachment structure that communicates with said bearing is an inner surface of said bore.

15. The assembly as recited in claim 9, wherein said bearing is intended to be bolted to said knuckle.

16. The assembly as recited in claim 9, wherein said bearing has includes an inner race and an outer race and said bearing outer race is integrally formed with said knuckle.

17. The assembly as recited in claim 9, wherein said bearing has includes an inner race and an outer race and said bearing inner race is integrally formed with said wheel hub neck portion.

18. The assembly as recited in claim 9, wherein said inner portion of said flange face and said outer portion of said flange face have a flatness of at least 20 μm or less.

19. The assembly as recited in claim 9, wherein said run-out between said flange face and an axis of rotation of said bearing is minimized.

20. The assembly as recited in claim 9, herein said run-out between said flange face and a bearing axis of rotation is 14 μm or better.

21. A method for manufacturing a wheel hub assembly, comprising:

providing a knuckle in communication with a bearing;

providing a wheel hub having a neck portion and a flange portion, said flange portion having a flange face with an inner portion, an outer portion, and a relief channel disposed between said inner portion and said outer portion;

forming a plurality of bolt receiving apertures in said relief channel;

journaling said neck portion of said wheel hub into communication with a said bearing to allow rotation of said wheel hub about a bearing axis;

clamping said knuckle, bearing, and wheel hub together;

final finishing said inner portion and said outer portion of said flange face whereby wherein said inner portion and said outer portion are co-planar whereby and wherein lateral run-out of said flange face to a brake rotor is minimized; and

wherein said final finishing step includes finishing said inner portion and said outer portion of said flange face such that they have a flatness of at least 20 μm or less.

22. The method as recited in claim 21, further comprising:

finishing said inner portion and said outer portion of said flange face prior to said final finishing step.

23. The method as recited in claim 21, further comprising:

locating said assembly in a clamping fixture.

24. The method as recited in claim 21, further comprising:

press-fitting a wheel bolt into each of said plurality of bolt receiving apertures prior to said step of final finishing.

25. The method as recited in claim 21, further comprising:

forming said relief channel in said flange face through machining.

26. The method as recited in claim 21, further comprising:

forming said relief channel in said flange face through forging.

27. The method as recited in claim 21, further comprising:

press-fitting said bearing into a bore in said knucklebore.

28. The method as recited in claim 21, further comprising:

integrally forming an outer race of said bearing with a said knuckle.

29. The method as recited in claim 21, further comprising:

integrally forming an inner race of said bearing with said neck portion of said wheel hub.

30. The method as recited in claim 21, further comprising:

securing said bearing to a said knuckle.

31. The method as recited in claim 21, wherein parallelism between said inner portion and said outer portion of said flange face and a plurality of brake caliper ears is maintained.

32. The method as recited in claim 21, wherein said final finishing step provides run-out between said flange face and said bearing axis of rotation of 14 μm or better or less.

33. A method for manufacturing a wheel end assembly, comprising:

providing a knuckle in communication with a bearing;

providing a wheel hub having a neck portion and a flange portion said flange portion having a flange face;

forming a relief channel in said flange face such that said flange face has an inner portion and an outer portion;

forming a plurality of bolt receiving holes in said relief channel;

clamping said knuckle, bearing, and wheel hub in a fixture;

finishing said flange face in order to flatten said flange face inner portion and said flange face outer portion; and

final finishing said inner portion and said outer portion of said flange face whereby wherein lateral run-out of said flange face is minimized, and wherein said inner portion and said outer portion each have a flatness of at least 20 μm or less.

34. The method as recite recited in claim 33, wherein said step of final finishing including includes forming said inner portion and said outer portion such that they are co-planar.

35. The method as recited in claim 33, wherein parallelism between said inner portion and said outer portion of said flange face and a plurality of brake caliper ears is maintained.

36. The method as recited in claim 33, further comprising:

locating the wheel end assembly into a fixture assembly prior to said step of final finishing.

37. The method as recited in claim 33, further comprising: providing a wherein said knuckle having includes a bearing retention structure formed therein.

38. The method as recited in claim 37, wherein said bearing retention structure is a generally circular bore formed in said knuckle.

39. The method as recited in claim 38, further comprising:

snap-fitting said bearing having an inner race and an outer race into said bore.

40. The method as recited in claim 39, wherein said bearing is located in said bore between a lower shoulder portion and an upper snap ring.

41. The method as recited in claim 38, wherein said bearing is only partially disposed in said bore.

42. The method as recited in claim 37, wherein said bearing retention structure is disposed on an upper surface of said knuckle.

43. The method as recited in claim 33, wherein said bearing is secured to a said knuckle.

44. The method as recited in claim 33, wherein said relief channel is formed in said flange face through machining.

45. The method as recited in claim 33, wherein said relief channel is conned formed in said flange face through forging.

46. The method as recited in claim 33, further comprising:

integrally forming an outer race of said bearing with said knuckle.

47. The method as recited in claim 33, further comprising:

integrally forming an inner race of said bearing with said neck portion of said wheel hub.

48. The method as recited in claim 33, further comprising:

press-fitting a wheel bolt into each of said plurality of bolt receiving holes prior to said step of final finishing.

49. The method as recited in claim 33, wherein wheel bolts are passed through each of said plurality of bolt receiving holes when a wheel is attached to said wheel hub.

50. A wheel hub assembly, comprising:

a bearing structure;

a knuckle in communication with said bearing structure;

a wheel hub having a neck portion and a flange portion with a flange face, said neck portion being in rotatable communication with said bearing;

a relief channel formed in said flange face and dividing said flange face into an inner portion and an outer portion; and

wherein said inner portion and said outer portion of said flange face have a flatness of at least 20 μm or less; and

wherein run-out of said flange face with respect to an axis of rotation of said bearing and said knuckle is minimized to 14 μm or less.

51. The wheel hub assembly as recited in claim 50, further comprising:

a knuckle having a plurality of apertures formed therein in said knuckle for attachment of said knuckle to a vehicle, said knuckle intended to communicate with said bearing.

52. The wheel hub assembly as recited in claim 50, wherein said inner portion and said outer portion of said flange face have a flatness of at least 14 μm or less.

53. The wheel hub assembly as recited in claim 50, wherein said neck portion of said wheel hub is press fit into communication with said bearing.

54. The wheel hub assembly as recited in claim 50, wherein said bearing has an inner race and an outer race and said outer race is integrally formed with a knuckle.

55. The wheel hub assembly as recited in claim 50, wherein said bearing has an inner race and an outer race and said inner race is integrally formed with said neck portion of said wheel hub.

56. The wheel hub assembly as recited in claim 50, wherein said relief channel is formed through forging.

57. The wheel hub assembly as recited in claim 50, wherein said relief channel is formed through machining.

58. A wheel hub assembly comprising:

a knuckle;

a bearing structure that is intended to communicate in communication with a knuckle;

a wheel hub having a neck portion and a flange portion, said neck portion being in rotatable communication with said bearing;

a flange face formed on said flange portion formating mating with a brake rotor; and

a relief channel formed in said flange face, which divides said flange face into an inner portion and an outer portion;

whereby wherein literal run-out of said flange face with respect to said brake rotor, an axis of rotation of said bearing, said knuckle, and said brake rotor is minimized to at least 20 14 μm or less.

59. The wheel hub assembly as recited in claim 58, wherein said inner portion and said outer portion have a flatness of at least 20 μm or less.

60. The wheel hub assembly as recited in claim 58, further comprising: a wherein said knuckle having includes a plurality of apertures formed therein for attachment of said knuckle to a vehicle, said knuckle intended to communicate with said bearing.

61. The wheel hub assembly as recited in claim 58, wherein said neck portion of said wheel hub is press fit into communication with said bearing.

62. The wheel hub assembly as recited in claim 58, wherein said bearing has an inner race and an outer race, said outer race being integrally formed with a knuckle.

63. The wheel hub assembly as recited in claim 58, wherein said bearing has an inner race and an outer race, said inner race being integrally formed with said neck portion of said wheel hub.

64. A method for manufacturing a wheel end assembly, comprising:

providing a knuckle in communication with a bearing;

providing a wheel hub having a neck portion and a flange portion, said flange portion having a flange face;

forming a relief channel in said flange face such that said flange face has an inner portion and an outer portion;

forming a plurality of bolt receiving holes in said relief channel;

inserting a through bolt into each of said plurality of bolt receiving holes;

clamping said knuckle, bearing, and wheel hub in a fixture;

final finishing said flange face in order to flatten said inner portion and said outer portion such that they have a flatness of at least 20 μm or less.

65. The method as recited in claim 64, wherein said step of final finishing flattens said inner portion and said outer portion such that they have a flatness of at least 14 μm or less.

66. The method as recited in claim 64, further comprising:

finishing said inner portion and said outer portion of said flange face prior to said final finishing step.

67. The method as recited in claim 64, further comprising:

placing said neck portion of said wheel hub in communication with a said bearing to allow rotation of said wheel hub about a bearing axis.

68. The method as recited in claim 67, further comprising:

integrally forming an outer race of said bearing with a said knuckle.

69. The method as recited in claim 67, further comprising:

integrally forming an inner race of said bearing with said neck portion of said wheel hub.

70. The method as recited in claim 67, wherein said stop step of final finishing includes minimizing run-out between said flange face and said bearing axis of rotation to at least 20 μm or less.

71. A wheel hub assembly, comprising:

a knuckle in communication with a bearing;

a wheel hub having a neck portion and a flange portion, said neck portion in rotational communication with said bearing;

a flange face formed on said flange portion;

a relief channel formed in said flange face and dividing said flange face into an inner portion and an outer portion;

a plurality of bolt receiving apertures formed in said relief channel;

whereby wherein lateral run-out of said flange face with respect to a brake rotor an axis of rotation of said knuckle, said bearing, and said brake rotor is minimized to at least 20 14 μm or less.

72. The wheel hub assembly as recited in claim 71, wherein said inner portion and said outer portion have a flatness of at least 20 μm or less.

73. The wheel hub assembly as recited in claim 71, further comprising:

a bearing in communication with said neck portion allowing said flange face to rotate about a bearing axis of rotation.

74. The wheel hub assembly as recited in claim 73 71, wherein said bearing has an inner race and an outer race, said inner race being integrally formed with said neck portion.

75. A wheel hub assembly, comprising:

a knuckle in communication with a bearing;

a wheel hub having a neck portion and a flange portion, said neck portion in communication with said bearing to rotate about an axis of rotation of said bearing and said knuckle;

a flange face formed on said flange portion;

a relief channel formed in said flange face and dividing said flange face into an inner portion and an outer portion;

a plurality of bolt receiving apertures formed in said relief channel;

wherein said inner portion and said outer portion have a flatness of at least 20 μm or less; and

wherein lateral run-out of said flange face with respect to an axis of rotation of said bearing and said knuckle is 14 μm or less.

76. The wheel hub assembly as recited in claim 75, further comprising:

a bearing in communication with said neck portion allowing said flange face to rotate about a bearing axis of rotation.

77. The wheel hub assembly as recited in claim 76, wherein lateral run-out of said flange face to said bearing axis of rotation is minimized to at least 20 μm.

78. The wheel hub assembly as recited in claim 75, wherein said inner portion and said outer portion have a flatness of at least 14 μm or less.

79. A method for manufacturing a wheel hub assembly, comprising:

providing a knuckle in communication with a bearing;

providing a wheel hub having a neck portion in rotational communication with said bearing, and a flange portion, said flange portion having a flange face;

forming a relief channel in said flange face such that said flange face has an inner portion and outer portion;

inserting one of a plurality of wheel bolts through a respective one of a plurality of wheel bolt apertures formed in said relief channel; and

clamping said knuckle, bearing, and wheel hub in a fixture; and

final finishing said flange face such that lateral run-out of said flange face with respect to an axis of rotation of said knuckle and said bearing is minimized to at least 20 14 μm or less.

80. The method as recited in claim 79, further comprising:

finishing said flange face prior to said step of final finishing.

81. The method as recited in claim 79, wherein said step of final finishing includes increasing the flatness of said flange face to at least 20 μm or less or less.

82. The method as recited in claim 79, wherein said step of final finishing includes minimizing the flatness of said flange face to at least 14 μm or less.

83. The method as recited in claim 79, further comprising:

placing a bearing in communication with said neck portion thereby allowing said flange face to rotate about a bearing axis of rotation.

84. The method as recited in claim 83 82, wherein said bearing has an inner race and an outer race and said outer race is integrally formed with said neck portion.