Abstract: A vehicle body and frame assembly includes a pair of longitudinally extending side rails having a plurality of transverse cross members extending therebetween. The cross member is a multiple piece structure, including a central portion having a pair of end portions secured thereto. The central portion of the cross member is preferably formed from a first metallic material, while the end portions are preferably both formed from a second metallic material. The end portions of the cross member are preferably formed from the same metallic material as the respective side rails to which they are secured. The end portions of the cross member can be secured to the ends of the central portion by any desired process, such as by magnetic pulse welding. Similarly, the cross member can be secured to the side rails by any desired process, such as by magnetic pulse welding or by conventional welding. The end portions of the cross member can extend either partially or completely through the respective side rails.

Abstract: A pair of metallic components, such as a pair of metallic structural components for a vehicular body and frame assembly, are permanently joined using a magnetic pulse welding process. Initially, a first metallic component is provided having a first aperture that is formed through a first side and a second aperture having a hollow cylindrical flange portion that is formed through a second side. A second metallic component is provided having a surface that extends at an angle relative to the flange portion. The angled surface may be provided in the form of either an enlarged region or a reduced region on the second metallic component. The first and second metallic components are arranged such that the flange portion of the first metallic component overlaps the surface of the second metallic component.

Abstract: A method for high velocity hydroforming a vehicle frame member including providing a hollow tubular member and a die having an internal die cavity. The tubular member is positioned within the die cavity and filled with a fluid. A shock wave is created within the fluid, thereby causing hyperplastic forming of the tubular member to expand it outwardly into conformance with the shape of the die cavity. The shock wave can be created by discharging an electric arc between a pair of electrodes submerged within the fluid. The ends of the tubular member can be fed into the die cavity during expansion to provide for a relatively uniform wall thickness in the deformed tubular member.

Abstract: A vehicle body and frame assembly includes a pair of longitudinally extending side rails having a plurality of transverse cross members extending therebetween. The cross member is a multiple piece structure, including a central portion having a pair of end portions secured thereto. The central portion of the cross member is preferably formed from a first metallic material, while the end portions are preferably both formed from a second metallic material. The end portions of the cross member are preferably formed from the same metallic material as the respective side rails to which they are secured. The end portions of the cross member can be secured to the ends of the central portion by any desired process, such as by magnetic pulse welding. Similarly, the cross member can be secured to the side rails by any desired process, such as by magnetic pulse welding or by conventional welding. The end portions of the cross member can extend either partially or completely through the respective side rails.

Abstract: A method is disclosed for manufacturing a vehicle body and frame assembly including a pair of side rails, each of which is formed from a single closed channel structural member that extends the entire length of the vehicle body and frame assembly and is deformed into a desired shape by hydroforming. The first step in the process is to provide a length of stock material, preferably a tubular metallic workpiece, having a predetermined length. The tubular workpiece is then typically pre-bent by a conventional tube bending apparatus to have some or all of the bends in the side rails to be formed. The bends initially formed in the workpiece during this pre-bending step usually do not have the exact angles and shapes which result in the final product. Rather, this initial pre-bending operation is performed to facilitate the insertion of the workpiece within a die cavity defined by cooperating die sections of a hydroforming die.

Abstract: A method of manufacturing a vehicle frame assembly includes the initial steps of providing first and second side rails and providing first and second cross members. Each of the first and second cross members has first and second ends extending from a central portion. A desired torsional stiffness is determined for the first cross member. In response to this determination, the first and second ends of the first cross member are enlarged so as to achieve the desired torsional stiffness for the cross member. A similar process can be conducted for the second cross member. Then, the first ends of the first and second cross members are secured to the first side rail, and the second ends of the first and second cross members are secured to the second side rail to form a vehicle frame assembly.