Abstract: A space frame includes a pair of laterally spaced, longitudinally extending side rail structures and longitudinally spaced pairs of laterally spaced upright structures having joints at their lower ends with the pair of side rail structures. The longitudinal spaced pairs of laterally spaced upright structures extend upwardly from the side rails structures and define a plurality of pairs of pillars, including a pair of forward A pillars, a longitudinally spaced pair of B pillars, and a longitudinally spaced pair of rearward end pillars. A pair of the side roof structures has joints with the pair of A pillars. The pair of side roof structures extends longitudinally rearwardly from the pair of A pillars and have joints with the pair of B pillars and with the pair of rearward end pillars. Longitudinally spaced cross structures have joints with the pair of side rail structures, with the pair of A pillars and with the pair of side roof structures.

Abstract: A method is provided for roll-forming an I-beam structure having a web and a pair of opposing flanges at each end of the web. The method includes the steps of providing a flat blank having a thickness generally equal to a thickness of the web of the I-beam to be formed. The blank has a longitudinal axis, a central portion and opposing ends. Each of the blank ends is split along the longitudinal axis to form first and second flange portions at each of the ends. Each of the first and second flange portions has an edge directed away from the central portion. The flange portions are then bent about the longitudinal axis by moving each of the edges in a direction towards the central portion to form a mass of material at each of the blank ends. The mass of material is compacted at each of the blank ends to define the flanges. Each flange is disposed generally transverse with respect to the longitudinal axis and has a thickness generally equal to the thickness of the web.

Abstract: A space frame includes a pair of laterally spaced, longitudinally extending side rail structures and longitudinally spaced pairs of laterally spaced upright structures having joints at their lower ends with the pair of side rail structures. The longitudinal spaced pairs of laterally spaced upright structures extend upwardly from the side rails structures and define a plurality of pairs of pillars, including a pair of forward A pillars, a longitudinally spaced pair of B pillars, and a longitudinally spaced pair of rearward end pillars. A pair of the side roof structures has joints with the pair of A pillars. The pair of side roof structures extends longitudinally rearwardly from the pair of A pillars and have joints with the pair of B pillars and with the pair of rearward end pillars. Longitudinally spaced cross structures have joints with the pair of side rail structures, with the pair of A pillars and with the pair of side roof structures.

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 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.