Abstract: A laser blanking device for high speed cutting of a rapidly fed strip of coil stock is disclosed and includes a support frame extending along a first longitudinal axis and a conveyor supported by the support frame. A strip of coil stock material is fed onto the conveyor at a pinch roll located near a first end of the frame. Transverse, moveable gantries above the conveyor suspend lasers. A pinch roll located near a second end of the frame assists movement of the material. Multiple laser cutting operations are simultaneously performed on the material as it moves along the device, and a laser head suspended from a gantry situated after the second pinch roll completes a cut that separates a blank from the remainder of the stock material.

Abstract: A laser blanking device for high speed cutting of a rapidly fed strip of coil stock includes a pin conveyor traveling a recurring loop along a longitudinal axis. At least two moveable gantries are supported above the pin conveyor. Each gantry is capable of moving at least a limited length along the longitudinal axis. At least one moveable laser head is suspended on each gantry, and the laser heads are capable of moving along the corresponding gantry along multiple axes transverse to or parallel to the longitudinal axis of the device. The device further has an entry pinch roll assembly and a second pinch roll assembly positioned at opposed ends of the conveyor. A pair of pinch rollers cooperates with each pinch roll assembly to apply tension to the strip traveling therebetween. Each pinch roller continually feeds the moving strip along the conveyor while the laser heads situated between the pinch roll assemblies move and progressively cut a perimeter portion of a blank or cut-out from the moving strip.

Abstract: A vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted is manufactured by initially casting a node that includes a body portion having a plurality of mounting portions. A first structural member is secured to each of the mounting portions of the node. Second structural members are secured to the first structural members to form a vehicular frame assembly upon which a body portion and other components of a vehicle can be mounted. If desired, a plurality of nodes is initially cast that each include a body portion having a plurality of mounting portions. A plurality of structural members is secured to the plurality of nodes to form the vehicular frame assembly.

Abstract: A method of manufacturing a node for joining a plurality of structural members together, such as in a vehicular body and frame assembly, is well suited for joining structural members that are formed from differing materials. An insert is provided having a node securing portion and a mounting portion that is adapted to have a structural member secured thereto. A node is formed about the node securing portion of the insert for joining a plurality of structural members together. The insert can be formed from a first material, while the node can be formed from a second material that is different from the first material. The insert can be provided with a node securing portion having at least one aperture or protrusion formed therein, and the node can be formed within or about the aperture or protrusion. A plurality of inserts can be provided, each having a node securing portion and a mounting portion, and the node can be formed about each of the node securing portions of the inserts.

Abstract: An apparatus and method of applying a lubricating material to an outer surface of a workpiece. Initially, a workpiece is provided that is preferably formed from a closed channel structural member having a circular or box-shaped cross sectional shape. Lubricating material is applied to an outer surface of the workpiece. In a second step of the method, the workpiece may be heat treated. The workpiece is then heated to elevate the temperature of the workpiece so as to cause the lubricating material to dry substantially immediately on the workpiece, thereby providing a coating of lubricating material having a substantially uniform thickness. In a fourth step of the method, a deforming process is performed on the workpiece during the period of time following the heat treatment process, and after applying the lubricating material, in which the workpiece retains the full or partial softening characteristics.

Abstract: A method for performing a hydroforming operation on a hollow workpiece includes the initial step of filling the interior of the workpiece with a hydroforming fluid. The pressure exerted by the hydroforming fluid against the interior of the workpiece is below the yield strength of the workpiece so as to not change the shape of the workpiece. Then, first and second die sections of the hydroforming apparatus are closed about the workpiece. The movement of the two die sections causes some mechanical deformation of the workpiece, but the presence of the hydroforming fluid within the workpiece prevents the amount of this mechanical deformation of the hollow workpiece from being undesirably large. Thereafter, the pressure exerted by the hydroforming fluid against the interior of the workpiece is increased to above the yield strength of the workpiece. As a result, the workpiece is deformed into engagement with the first and second die sections of the hydroforming die.

Abstract: A hydroforming apparatus includes upper and lower platens that are connected together by tie rods extending through respective compression tubes. An upper die section is carried on the upper platen by a generally C-shaped suspension arm, while a lower die section is carried on the lower platen. The upper and lower die sections have recessed areas formed therein that define a die cavity. Lift assemblies are provided on the lateral ends of the hydroforming apparatus for selectively elevating the lower die section upwardly into engagement with the upper die section. When the lower die section is elevated by the lift assemblies, a workpiece is enclosed within the die cavity. A bolster is then moved between the hydroforming die and the lower platen. A cylinder array containing a plurality of pistons is next hydraulically actuated so as to securely clamp the hydroforming die between the cylinder array and the lower platen.

Abstract: An apparatus and method for manufacturing a vehicle frame component allow a preliminary heat treatment process to be performed in a relatively quick and easy manner so as to facilitate the subsequent performance of a bending or other deforming process. Initially, a workpiece that is to be manufactured into the vehicle frame component is provided. The workpiece is preferably a closed channel structural member formed from an aluminum alloy and having a circular or box-shaped cross sectional shape. The workpiece is subjected to a scanning heat treatment process, wherein the workpiece is heat treated in a continuous and longitudinal manner from one end to the other. Preferably, the workpiece is supported vertically during the scanning heat treatment process to prevent the shape thereof from becoming distorted.

Abstract: A method for performing a hydroforming operation on a hollow workpiece includes the initial step of filling the interior of the workpiece with a hydroforming fluid. The pressure exerted by the hydroforming fluid against the interior of the workpiece is below the yield strength of the workpiece so as to not change the shape of the workpiece. Then, first and second die sections of the hydroforming apparatus are closed about the workpiece. The movement of the two die sections causes some mechanical deformation of the workpiece, but the presence of the hydroforming fluid within the workpiece prevents the amount of this mechanical deformation of the hollow workpiece from being undesirably large. Thereafter, the pressure exerted by the hydroforming fluid against the interior of the workpiece is increased to above the yield strength of the workpiece. As a result, the workpiece is deformed into engagement with the first and second die sections of the hydroforming die.

Abstract: A vehicle frame assembly includes a first vehicle frame component that is formed by deforming a closed channel structural member to have a relatively small end portion and a relatively large end portion. A member is provided having first and second ends. The relatively large end portion of the closed channel structural member is secured to the first end portion of the member to form the first vehicle frame component. A plurality of second vehicle frame components are provided. The first vehicle frame component and the plurality of second vehicle frame components are secured together to form the vehicle frame assembly.

Abstract: A method of manufacturing a node for joining a plurality of structural members together, such as in a vehicular body and frame assembly, is well suited for joining structural members that are formed from differing materials. An insert is provided having a node securing portion and a mounting portion that is adapted to have a structural member secured thereto. A node is formed about the node securing portion of the insert for joining a plurality of structural members together. The insert can be formed from a first material, while the node can be formed from a second material that is different from the first material. The insert can be provided with a node securing portion having at least one aperture or protrusion formed therein, and the node can be formed within or about the aperture or protrusion. A plurality of inserts can be provided, each having a node securing portion and a mounting portion, and the node can be formed about each of the node securing portions of the inserts.

Abstract: A vehicle frame assembly includes a first vehicle frame component that is formed by deforming a closed channel structural member to have a relatively small end portion and a relatively large end portion. A member is provided having first and second ends. The relatively large end portion of the closed channel structural member is secured to the first end portion of the member to form the first vehicle frame component. A plurality of second vehicle frame components are provided. The first vehicle frame component and the plurality of second vehicle frame components are secured together to form the vehicle frame assembly.

Abstract: A vehicle frame assembly includes a first vehicle frame component that is formed by deforming a closed channel structural member to have a relatively small end portion and a relatively large end portion. A member is provided having first and second ends. The relatively large end portion of the closed channel structural member is secured to the first end portion of the member to form the first vehicle frame component. A plurality of second vehicle frame components are provided. The first vehicle frame component and the plurality of second vehicle frame components are secured together to form the vehicle frame assembly.

Abstract: A hydroforming apparatus includes upper and lower platens that are connected together by tie rods extending through respective compression tubes. An upper die section is carried on the upper platen by a generally C-shaped suspension arm, while a lower die section is carried on the lower platen. The upper and lower die sections have recessed areas formed therein that define a die cavity. Lift assemblies are provided on the lateral ends of the hydroforming apparatus for selectively elevating the lower die section upwardly into engagement with the upper die section. When the lower die section is elevated by the lift assemblies, a workpiece is enclosed within the die cavity. A bolster is then moved between the hydroforming die and the lower platen. A cylinder array containing a plurality of pistons is next hydraulically actuated so as to securely clamp the hydroforming die between the cylinder array and the lower platen.

Abstract: A hydroforming apparatus includes an upper platen carrying an upper die section and a lower platen carrying a lower die section. The platens are connected together by tie rods extending through respective compression tubes. The upper and lower die sections have recessed areas formed therein that define a die cavity. When the lower die section is moved to a lowered position, a workpiece can be disposed in the recessed area formed therein. Then, the lower die section and the workpiece are elevated by cylinders such that the workpiece is enclosed within the die cavity and mechanically deformed by the cooperated upper and lower die sections. A support block is then moved between the hydroforming die and the lower platen. A cylinder array containing a plurality of pistons is next hydraulically actuated so as to securely clamp the hydroforming die between the cylinder array and the lower platen.

Abstract: A method for forming a closed channel structural member having a central portion that is enlarged relative to the end portions thereof is disclosed. Initially, first and second tubes are formed in respective hydroforming dies to have desired shapes that are preferably characterized by a relatively large diameter first end portions and relatively small diameter second end portions. Each of the two tubes is then oriented such that the relatively large diameter first end portions are disposed adjacent to one another. Lastly, the relatively large diameter first end portions are joined together in any conventional manner, such as by butt welding, to form a unitary member characterized by a relatively large diameter central portion extending between a pair of relatively small diameter end portions. The unitary member can be used as a component, such as a side rail, of a vehicle body and frame assembly.

Abstract: A method of manufacturing a sleeve mechanism without the use of machines by using a hydroforming process. The method includes the steps of providing an inner sleeve, an intermediate sleeve, and an outer sleeve concentrically within one another. The concentric sleeves are then expanded by using a hydroforming process such that an external thread is formed on the inner sleeve and an internal thread is formed on the outer sleeve. After the hydroforming process, the intermediate sleeve is removed by using any desired manner, such as melting or chemical dissolution. The relatively small space remaining between the inner and outer sleeves allow them to freely rotate about each other to ensure smooth operation of the screw and sleeve mechanism. Alternatively, the inner and outer sleeves may be hydroformed in separate operations.

Abstract: An apparatus and method are provided for initially performing a heat treatment process on a closed channel structural member to facilitate the subsequent performance of a magnetic pulse welding process so as to manufacture a vehicle frame component or a portion of a vehicle frame assembly. Initially, a workpiece is provided that is preferably formed from a closed channel structural member having a circular or box-shaped cross sectional shape. The workpiece is subjected to a scanning heat treatment process, wherein the workpiece is heat treated in a continuous and longitudinal manner from one end to the other. Preferably, the workpiece is supported vertically during the scanning heat treatment process to prevent the shape thereof from becoming distorted. The scanning heat treatment process is preferably a retrogression heat treatment process, wherein the workpiece is rapidly heated to a sufficient temperature that provides for full or partial softening thereof, followed by relatively rapid cooling.

Abstract: A vehicle frame assembly includes a first vehicle frame component that is formed by deforming a closed channel structural member to have a relatively small end portion and a relatively large end portion. A member is provided having first and second ends. The relatively large end portion of the closed channel structural member is secured to the first end portion of the member to form the first vehicle frame component. A plurality of second vehicle frame components are provided. The first vehicle frame component and the plurality of second vehicle frame components are secured together to form the vehicle frame assembly.

Abstract: A hydroforming apparatus includes an upper platen carrying an upper die section and a lower platen carrying a lower die section. The platens are connected together by tie rods extending through respective compression tubes. The upper and lower die sections have recessed areas formed therein that define a die cavity. When the lower die section is moved to a lowered position, a workpiece can be disposed in the recessed area formed therein. Then, the lower die section and the workpiece are elevated by cylinders such that the workpiece is enclosed within the die cavity and mechanically deformed by the cooperated upper and lower die sections. A support block is then moved between the hydroforming die and the lower platen. A cylinder array containing a plurality of pistons is next hydraulically actuated so as to securely clamp the hydroforming die between the cylinder array and the lower platen.