Abstract: A vehicle part suitable to form a part of a rigid vehicle assembly, such as a vehicle frame assembly or the like. The vehicle part is formed from a cylindrical blank having a predetermined wall thickness and a predetermined peripheral dimension. The cylindrical blank is bent and hydroformed to provide a tubular wall having a central bend therein of at least approximately 30.degree. and opposite angularly related end portions. The central bend has a peripheral dimension in excess of approximately 10% of the predetermined peripheral dimension of the cylindrical blank. The central bend includes a concave portion free of wrinkles and a convex portion having a wall thickness within plus or minus 10% of the predetermined wall thickness of the cylindrical blank.

Abstract: A method and apparatus for forming an exterior body panel for a motor vehicle.

Abstract: An apparatus for hydroforming a tubular metal blank comprises a die structure, a hydroforming fluid source, a hydraulically driven tube-end engaging structure, a hydraulically driven pressure intensifying structure, and a single hydraulic power source. The tube-end engaging structure seals opposite ends of the tubular metal blank in said die cavity and is movable to longitudinally compress the tubular metal blank. The tube-end engaging structure receives hydroforming fluid from said hydroforming fluid source and has a hydroforming fluid supplying outlet through which hydroforming fluid can be provided to the tubular metal blank. The hydraulically driven pressure intensifying structure is movable to pressurize the hydroforming fluid provided to the interior of the tubular metal blank and thereby expand a diameter of the blank.

Abstract: A die assembly for draw stamping sheet metal in a press. The die assembly has an upper die structure and a lower die structure, each constructed and arranged to me mounted on a press for reciprocal movement therebetween. The upper die structure and the lower die structure have complementary stamping surfaces for stamping sheet metal to a desired configuration. A clamping assembly and a stretching assembly grip the sheet metal along opposite sides of the complementary stamping surfaces and drivingly move apart in response to movement of the upper and lower die structures toward one another, thus pre-stretching the sheet metal as the upper and lower die structure are closed to stamp the sheet metal to a desired configuration.

Abstract: The present invention relates to a method and apparatus for forming an elongated tubular metal member from a tubular metal blank. The method comprises: i) placing a tubular metal blank having a generally oval cross-section into a die cavity and orienting the tubular metal blank such that a relatively larger cross-sectional dimension of the generally oval cross-section extends generally in a direction of the relatively larger cross-sectional dimension of the die cavity and such that a relatively smaller cross-sectional dimension of the generally oval cross-section extends generally in a direction of the relatively smaller cross-sectional dimension of the die cavity; ii) engaging and sealing opposite ends of the tubular metal blank; and iii) injecting fluid under pressure into the tubular metal blank so as to expand the tubular metal blank into conformity with the surfaces defining the die cavity and thereby transform the tubular metal blank into the elongated tubular metal member.

Abstract: A die assembly having die structures that are cooperable to define a die cavity into which a metallic tubular blank can be disposed. A first die structure is moveable to seal the die cavity, and after the die cavity is sealed, the first and second die structures are moveable to reduce the cross-sectional area of the die cavity and thereby deform the metallic tubular blank within the die cavity.

Abstract: The invention relates to a hollow camshaft consisting of a metal or metal alloy or plastic which can be cold-formed and heat-treated and has a fiber flow parallel to the exterior contours of the camshaft, and to a method for producing it comprising the steps of:Placing a pipe outlet element and filling it with fluid;Sealing at least the pipe section to be widened;Applying an internal high pressure suitable for widening the pipe section to produce an intermediate product pre-form, wherein, while the internal high pressure is applied, the hollow pipe is compressed against a movable die in the direction of its long axis in such a way that accumulations of material occur at approximately those places where it is intended to create cams;Shaping the intermediate product pre-form into a shape corresponding to a final camshaft shape by means of the internal high pressure shaping method, so that cams are shaped at the desired locations;If necessary, finishing the cams by heat-treatment.

Abstract: A method of hydroforming an angled tubular part comprising disposing an angled metal tubular blank within a generally correspondingly angled die cavity, the tubular blank having an exterior surface, wherein at an angled portion of the tubular blank, the exterior surface has a concave surface portion and a convex surface portion on generally opposite sides of the tubular blank, sealing opposite ends of the tubular blank, providing high pressure fluid to an interior of the tubular blank, expanding the blank into conformity with surfaces defining the die cavity as a result of said providing.

Abstract: A cradle assembly for a motor vehicle comprises a pair of spaced side frame members, a front cross frame member and a rear cross frame member. The front cross frame member is connected with front ends of the side frame members. The rear cross frame member extends between rear ends of the side frame members. The frame members are formed from tubular metal blanks by a hydroforming process in which each blank has fluid pressure provided internally thereto and thereby radially expanded so that the frame members have a peripheral configuration modified with respect to an original peripheral configuration of the associated blanks.

Abstract: A frame assembly for a motor vehicle and method of manufacturing the same. The method includes the steps of: forming a rearward frame module, forming a forward frame module, and forming a central frame module including a pair of longitudinal central frame siderails.

Abstract: A method for producing a hollow camshaft comprising i) forming a camshaft preform by providing a hollow metal pipe, expanding the hollow pipe at spaced longitudinal locations by applying pressurized fluid internally to the hollow pipe, axially compressing the hollow pipe during the expanding step to accumulate metal at the spaced longitudinal locations, the expanding and compressing steps forming a camshaft preform having cam preforms of associated predetermined widths in a longitudinal pipe direction; and ii) forming a final camshaft from the camshaft preform by axially compressing the camshaft preform while applying the pressurized fluid to reduce the predetermined widths of the cam preforms while shaping the camshaft preforms into the final camshaft, the final camshaft having cams of relatively smaller widths in the longitudinal direction than the predetermined widths of the cam preforms.

Abstract: A transmission clutch housing for transmitting a rotational motion from a driving shaft to a driven shaft in conjunction with a clutch plate assembly is formed from a single piece of metal. The housing includes a central web structure extending axially from an axis of rotation, a splined clutch-plate-engaging flange extending axially From the central web structure, and a rotational member coupling flange, which may be in the form of a pulley or a gear, also extending axially from the central web structure. In the method of forming the transmission clutch housing, a flat metal blank is placed on a spin forging device. A peripheral edge of the blank is split in a radial direction by a splitting tool to form two split portions. The two split portions are then spin formed into the splined clutch-plate-engaging flange and the rotational member coupling flange.

Abstract: A frame assembly for a motor vehicle and method of manufacturing the same. The method comprises the steps of: forming a rearward frame module, forming a forward frame module, and forming a central frame module comprising a pair of longitudinal central frame siderails.

Abstract: An improved method for fabricating a vehicle wheel from a one-piece sheet metal blank involves a nine station transfer die. In a first station, a sheet metal blank is drawn into a dish-shaped wall, a cylindrical outside wall, a first contour, and a first side wall. In the second station, the dish-shaped wall is reverse drawn to form a hub and an inside wall, and a valve hole is punched into the first contour. In the third station, the hub is flattened to be substantially perpendicular to an axial centerline of the partially fabricated wheel, and an outer peripheral edge of the first side wall is trimmed. In the fourth station, the inside wall is laterally formed so as to be in contact with the outside wall, and an outer peripheral edge of the first side wall is wiped over to form a flange. In the fifth station, a second contour is laterally formed. In the sixth station, a first offset and inner and outer hub-stiffening embosses are drawn into the hub.

Abstract: A rail frame assembly for a motor vehicle comprises a rearward frame module having a pair of generally parallel rearward frame rail members interconnected by a rearward cross-member assembly. A central frame module includes a pair of generally parallel central frame rail members interconnected by a central cross-member assembly, the central frame members each having a generally U-shaped transverse cross-sectional configuration including a vertical base wall portion and a pair of outwardly extending generally parallel horizontal wall portions extending from opposite ends of the base wall portion. The U-shaped central frame members are each bent between two spaced positions thereof, and one of the horizontal wall portions extending from one end of the base wall portion has metallic grains therein substantially stretched at a location between the spaced positions.

Abstract: A rail frame assembly for a motor vehicle comprises a rearward frame module having a pair of generally parallel rearward frame rail members interconnected by a rearward cross-member assembly. A central frame module includes a pair of generally parallel central frame rail members interconnected by a central cross-member assembly, the central frame members each having a generally U-shaped transverse cross-sectional configuration including a vertical base wall portion and a pair of outwardly extending generally parallel horizontal wall portions extending from opposite ends of the base wall portion. The U-shaped central frame members are each bent between two spaced positions thereof, and one of the horizontal wall portions extending from one end of the base wall portion has metallic grains therein substantially stretched at a location between the spaced positions.

Abstract: The invention concerns an impact-absorption device, particularly for vehicles, which is attached on one side to the bumper and on the other side to the longitudinal girder or another part of the vehicle-body structure. The device has a non-regenerative deforming unit designed to absorb energy when acted on by a force with a component in the direction of the longitudinal axis of the longitudinal girder. The deforming unit has at least two hollow deforming elements which engage one inside the other, one of which being attached to the bumper while the other is attached to the longitudinal girder of the vehicle. If the device is crushed by a force component acting along its longitudinal axis, the deforming elements are telescoped into each other, deforming the material. The hollow deforming elements (12, 14) have a non-circular, preferably oval or angular, cross-section. In a particularly preferred embodiment, the hollow elements have ribs.