Abstract: A riveting yoke assembly (11) comprises a yoke (30), a force applying mechanism (22) and a rivet forming device (34, 36). The yoke has a first end (38), a second end (40), and a middle section (42) coupled between the first and second ends (38, 40). An opening (44) is formed through the yoke between the first and second ends. The force applying mechanism (22) is coupled to the first end (38) of the yoke (30). The lower rivet forming device (36) is removably coupled to the second end (40) of the yoke. The lower rivet forming device (36) has a base end (46) attached to the second end (40) of the yoke (30) and a forming end (48) with a recess (50) to form rivets (17). The recess (50) has a concave, interior surface (52) having an annular step (54) positioned between a top edge (56) of the interior surface (52) and a bottom-most point (58) of the interior surface (52) in order to properly align the rivet (17).

Abstract: A frame assembly for a motor vehicle includes a tubular frame and a support tube. The tubular frame includes a first portion connected to a second portion. The first and second portions define a hollow cavity therebetween. A support tube is positioned within the hollow cavity between the first and second portions. The support tube has an exterior surface. The first and second portions include first and second indents respectively formed therein. The first and second indents engage the exterior surface of the support tube to secure the support tube between the first and second portions.

Abstract: A riveting yoke assembly (11) comprises a yoke (30), a force applying mechanism (22) and a rivet forming device (34,36). The yoke has a first end (38), a second end (40), and a middle section (42) coupled between the first and second ends (38,40). An opening (44) is formed through the yoke between the first and second ends. The force applying mechanism (22) is coupled to the first end (38) of the yoke (30). The lower rivet forming device (36) is removably coupled to the second end (40) of the yoke. The lower rivet forming device (36) has a base end (46) attached to the second end (40) of the yoke (30) and a forming end (48) with a recess (50) to form rivets (17). The recess (50) has a concave, interior surface (52) having an annular step (54) positioned between a top edge (56) of the interior surface (52) and a bottom-most point (58) of the interior surface (52) in order to properly align the rivet (17).

Abstract: A method for expanding tubular blanks includes pre-expanding or initially expanding a section of the tube by forcing a punch into an open end of the tube. The punching process may be repeated to achieve up to approximately 50% expansion from the original configuration of the blank. Then, the same pre-expanded section can be further expanded by hydroforming such that the blank is filled with pressurized fluid to achieve further expansion of the initially expanded section up to approximately 100% expansion from the original configuration of the blank. As a final step, the open end of the expanded tube may be cut to its ultimate shape.