Abstract: A reinforcement received between facing surfaces of adjacent panels that may be part of a hinge pillar of a vehicle such as a pickup truck and the panels may be aluminum. The reinforcement may be a one-piece molded structure. The reinforcement includes ribs that extend between the facing surfaces in a lattice arrangement defining a plurality of cells. The cells may have a number of transverse walls defining a perimeter of a polygon. The polygonal cells may have a facing wall on one side of the cell closing the cell. The facing wall may have an adhesive that is applied to the reinforcement and expanded in a paint bake oven to secure the reinforcement to the adjacent panels.

Abstract: An extruded aluminum alloy tube for hydroforming into an automotive body component includes a wall defining a closed perimeter. The wall includes weld seams disposed in the wall and running longitudinally along the tube. An extruded pip is disposed on the wall and runs longitudinally along the tube. The pip is parallel to the seams and is configured to identify a location of the seams for alignment of the tube during manufacturing.

Abstract: A finite-element-analysis simulator may simulate a pre-bend operation of an object design, performed to a raw material in forming an object, to produce simulated pre-bend results, adjust stress tensor components of the simulated pre-bend results to eliminate residual elastic deformation from the simulated pre-bend results, and complete object simulation of the raw material using the adjusted simulated pre-bend results.

Abstract: A method of hydroforming a vehicle rail from an extruded aluminum tube includes the steps of positioning the extruded aluminum tube into a hydroforming die and partially closing the hydroforming die. Next is the step of applying a liquid under a first level of pressure to the extruded aluminum tube in the hydroforming die. This is followed by engaging an inner radius of a bend in the extruded aluminum tube with the hydroforming die before completely closing the hydroforming die and increasing the level of liquid pressure in the workpiece to a second level to form and hydro-pierce a part from the extruded aluminum tube.

Abstract: A galling-resistive insert is positioned on an outer surface of a mandrel assembly. The insert is secured at the outer surface of the mandrel assembly and functions to reduce galling of an inner surface of a tubular blank during a rotary-draw bending operation.

Abstract: A method of hydroforming a workpiece includes the steps of bending the workpiece into a first preliminary shape, pre-forming the workpiece into a second preliminary shape, induction annealing the workpiece at a temperature between 120-160° C. and hydroforming the workpiece to a desired shape.

Abstract: A method and tool for calibrating an extruded tube for use in a manufacturing operation. According to the method, the tube is stretched while in a clamping tool by approximately 3%. The tool encloses the tube while a stretching mechanism is clamped to opposite longitudinal ends of the tube and applies a stretching force to opposite ends of the tube. The tool includes a clamping mechanism that clamps the tube into a cavity and a stretching mechanism with clamps that are attached to opposite longitudinal ends of the tube to calibrate the tube by longitudinally stretching the tube.

Abstract: An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die.

Abstract: An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die.

Abstract: An electrohydraulic forming (EHF) tool having a pair of electrodes that can be used to generate a shockwave to facilitate forming a sheet metal blank against a forming die. The electrodes may be adjusted during the course of operation. This may be useful should continued use cause their efficiency to drop below a desired threshold.