Abstract: A method for manufacturing a hydroforming member includes the step of providing a blank (10). The blank (10) is defined by blank wall (16). The blank (10) is placed in a die assembly (14) having a die cavity (12) defined by a die surface (24). The blank (10) is expanded so that the blank wall (16) is forced against the die surface (24) to form the hydroformed member. A portion of the blank wall conforms against a wall-thinning element (26, 28) positioned along the die surface (24) to form a removable wall section (46, 50) in a portion of the blank wall (24). The removable wall section (46, 50) is then removed from the blank wall (16) to form an opening in the hydroformed member.

Abstract: A hydroforming apparatus includes a hydroforming die member and a hydroforming press. A fastener couples the press to the die member, the fastener having a shaft and a shoulder. A spacer positioned on the fastener spaces the die member from the press. The shaft is secured to the press housing. The shoulder is positioned within a slot in the die member configured to receive the shoulder as the shoulder is inserted into the slot in a direction transverse to a longitudinal axis of the fastener.

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 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 hydroforming apparatus includes a hydroforming die member and a hydroforming press. A fastener couples the press to the die member, the fastener having a shaft and a shoulder. A spacer positioned on the fastener spaces the die member from the press. The shaft is secured to the press housing. The shoulder is positioned within a slot in the die member configured to receive the shoulder as the shoulder is inserted into the slot in a direction transverse to a longitudinal axis of the fastener.

Abstract: A method for manufacturing a hydroforming member includes the step of providing a blank (10). The blank (10) is defined by blank wall (16). The blank (10) is placed in a die assembly (14) having a die cavity (12) defined by a die surface (24). The blank (10) is expanded so that the blank wall (16) is forced against the die surface (24) to form the hydroformed member. A portion of the blank wall conforms against a wall-thinning element (26, 28) positioned along the die surface (24) to form a removable wall section (46, 50) in a portion of the blank wall (24). The removable wall section (46, 50) is then removed from the blank wall (16) to form an opening in the hydroformed member.

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 method for forming a hollow part (18) that allows the use of hydroforming in cases where the part interconnects between sections having extreme variations in cross-section. A complete hollow part (18) is formed by joining a hydroformed hollow section with hollow sections. A method for securing a fastener sleeve (102) insert in a pre-fabricated hollow part (100) is also provided. In this method, the hollow part (100) is deformed slightly to form flanges (108) that secure the insert (102) in the part. Once the insert (102) is secure in the hollow part, fasteners can be applied to the part without collapsing it.

Abstract: An assembly of supporting members includes a first member overlapping a second member and positioned within a hollow interior of the second member. The hollow interior of the second member has a flange on which the first member rests. A leading edge of the first member may have a protrusion extending away from the first member towards the flange of the second member to protect the flange and the connection between the first and second members. The first and second members may be hydroformed with the protrusion being an integral element of the first member.

Abstract: A method for forming a hollow part (18) that allows the use of hydroforming in cases where the part interconnects between sections having extreme variations in cross-section. A complete hollow part (18) is formed by joining a hydroformed hollow section with hollow sections. A method for securing a fastener sleeve (102) insert in a pre-fabricated hollow part (100) is also provided. In this method, the hollow part (100) is deformed slightly to form flanges (108) that secure the insert (102) in the part. Once the insert (102) is secure in the hollow part, fasteners can be applied to the part without collapsing it.

Abstract: An assembly of supporting members includes a first member overlapping a second member and positioned within a hollow interior of the second member. The hollow interior of the second member has a flange on which the first member rests. A leading edge of the first member may have a protrusion extending away from the first member towards the flange of the second member to protect the flange and the connection between the first and second members. The first and second members may be hydroformed with the protrusion being an integral element of the first member.