Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A hydroforming assembly has a plurality of die structures that are mounted on a press for reciprocating movement between open and closed conditions. The die structures have cooperating die surfaces defining a die cavity when in the closed condition and receive a metallic tube blank when in the open conditions. A hydroforming fluid supply system has tube-end engaging structures that are movable to selectively and sealingly engage opposite ends of the tube blank. The hydroforming fluid supply system provides pressurized fluid into an interior of the tube blank in order to expand the tube blank outwardly into conformity with the die cavity. A punch extends within a passage of at least one of the die structures. The punch is movable between retracted and extended positions. A punch driving assembly drives the punch between the retracted and extended positions to punch a hole into the expanded tube blank.

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.