Abstract: Apparatus and method for mechanically and hydroform reconfigurating an elongated tubular workpiece in an elongated cavity between upper and lower tool subassemblies each composed of a plurality of independent tool segments movable axially, relative to the cavity axis, together or spaced from each other, and independently movable transversely of the cavity, usually vertically, in sequence, to grip the end portions of the workpiece while its ends are flared with tapered mandrels, and after the workpiece is filled with liquid, offset deform one workpiece portion while the tool segments are spaced apart and with axial infeed of workpiece material, then offset deform another portion with further axial infeed of workpiece material. Hydroforming pressure is then applied to partially expand the workpiece.

Abstract: Apparatus for mechanically and hydroform reconfigurating an elongated tubular workpiece in an elongated cavity between upper and lower tool subassemblies each composed of a plurality of independent tool segments movable axially, relative to the cavity axis, together or spaced from each other, and independently movable transversely of the cavity, usually vertically, in sequence, to grip the end portions of the workpiece while its ends are flared with tapered mandrels, and after the workpiece is filled with liquid, offset deform one workpiece portion while the tool segments are spaced apart and with axial infeed of workpiece material, then offset deform another portion with further axial infeed of workpiece material. Hydroforming pressure is then applied to partially expand the workpiece. Then after withdrawing segment spacing stops, forcing the tool segments together, and totally closing the tool, a greater hydroforming pressure is applied in the workpiece to expand it to the specific cavity configuration.