Abstract: In a method of making a control arm for a wheel suspension of a motor vehicle a blank of steel material having a tensile strength of at least 800 MPa is shaped, using a sheet metal forming process, into a shell body having a center web and plural flank portions extending from the center web in a same direction. The flank portions are connected by a latticed reinforcement made of plastic, without application of a heat treatment process.

Abstract: An adaptive crash structure of a vehicle body or chassis of a motor vehicle includes a first metal casting and a second metal casting. A deformation element in the form of a metal casting for absorbing energy interconnects and forms with the first and second metal castings a single piece construction through a casting process. The deformation element is comprised of a plurality of funnel-shaped wedge bodies which are disposed in succession, with neighboring wedge bodies being connected through intervention of a predetermined breaking web. Each wedge body is defined by a diameter, wherein the diameters of the wedge bodies are sized to allow the wedge bodies to move telescopically into one another when a limit stress is reached and the predetermined breaking webs rupture so as to effect a tight intergrip of the telescoping wedge bodies in a self-locking manner.

Abstract: In a method of making a tube, a sheet metal blank is placed in a U-shaped cavity of a lower mold of a shaping tool, and pressed into the cavity by a ram to shape the blank into a U-shaped configuration. In a next process step, the U-shaped blank is formed between an upper mold and a lower mold of a molding press into a tubular configuration. The upper and lower molds of the molding press with accommodated tubular profile are then clamped together and the clamped upper and lower molds are then removed from the molding press. Subsequently, the confronting longitudinal edges of the tubular profile are welded together via an opening that provides access to the longitudinal edges. After separation of the upper mold from the lower mold, another shaping cycle may begin.

Abstract: A structural part for a body or undercarriage of a motor vehicle includes a channel-shaped or hollow length portion made of steel sheet; and a bulkhead received for reinforcement in the length portion in an area of high stress. The bulkhead hereby extends in parallel relationship to the longitudinal axis of the length portion.

Abstract: Apparatus for heat-treating an elongate structural body part made from a blank compressed while being soft or from steel strip of hardenable 22 Mn B5 mod. steel sheet with a thickness of 1 mm to 3 mm, includes an apparatus for positioning the structural body part in substantially upright disposition. Placed in surrounding relationship to the structural body part is an induction element which can move from bottom to top, thereby being able to follow a contour of the structural body part and allowing to at least partially heat the structural body part to an austenitizing temperature suitable for hardening. Disposed adjacent to the induction element is a cooling unit which follows the induction element in movement direction. The induction element and the cooling unit are moveable relative to one another and connected to a tool carriage which is mounted to a column for movement in a vertical direction, in a transverse direction to the column and about a horizontal axis.

Abstract: An adaptive crash structure of a vehicle body or chassis of a motor vehicle includes a first metal casting and a second metal casting. A deformation element in the form of a metal casting for absorbing energy interconnects and forms with the first and second metal castings a single piece construction through a casting process. The deformation element is comprised of a plurality of funnel-shaped wedge bodies which are disposed in succession, with neighboring wedge bodies being connected through intervention of a predetermined breaking web. Each wedge body is defined by a diameter, wherein the diameters of the wedge bodies are sized to allow the wedge bodies to move telescopically into one another when a limit stress is reached and the predetermined breaking webs rupture so as to effect a tight intergrip of the telescoping wedge bodies in a self-locking manner.

Abstract: In a method of making a tube, a sheet metal blank is placed in a U-shaped cavity of a lower mold of a shaping tool, and pressed into the cavity by a ram to shape the blank into a U-shaped configuration. In a next process step, the U-shaped blank is formed between an upper mold and a lower mold of a molding press into a tubular configuration. The upper and lower molds of the molding press with accommodated tubular profile are then clamped together and the clamped upper and lower molds are then removed from the molding press. Subsequently, the confronting longitudinal edges of the tubular profile are welded together via an opening that provides access to the longitudinal edges. After separation of the upper mold from the lower mold, another shaping cycle may begin.

Abstract: An apparatus for hydraulic high-pressure forming of a sheet, the apparatus having a top tool and a bottom tool as well as at least one pressure generating unit arranged between the press ram of a mechanical press and the top tool and uses a pressurized medium from the pressure generating unit as a working fluid for hydraulic preforming of the sheet. Contact faces of the tools directly engage with the sheet surface along the clamping area thereof and act to seal off the forming area that are subjected to the working fluid solely by contact sealing.

Abstract: In a method of making a tube a sheet metal blank. having opposite longitudinal flanks is placed in a die of a shaping tool. At least one of the longitudinal flanks of the sheet metal is provided with a contact projection suitable for resistance pressure welding. The blank is pressed into a U-shaped cavity of the cavity by a ram to shape the blank into a U-shaped configuration which is then shaped between an upper mold and a lower mold of a molding press into a tubular profile with the longitudinal flanks confronting one another. The upper mold has in an area of the confronting longitudinal flanks oppositely poled electrode strips which are insulated against one another.

Abstract: In a method of making a control arm for a wheel suspension of a motor vehicle a blank of steel material having a tensile strength of at least 800 MPa is shaped, using a sheet metal forming process, into a shell body having a center web and plural flank portions extending from the center web in a same direction. The flank portions are connected by a latticed reinforcement made of plastic, without application of a heat treatment process.

Abstract: A structural part for a body or undercarriage of a motor vehicle includes a channel-shaped or hollow length portion made of steel sheet; and a bulkhead received for reinforcement in the length portion in an area of high stress. The bulkhead may hereby extend transversely or in parallel relationship to the longitudinal axis of the length portion.

Abstract: An apparatus for hydraulic high-pressure forming of a sheet, the apparatus having a top tool and a bottom tool as well as at least one pressure generating unit arranged between the press ram of a mechanical press and the top tool and uses a pressurized medium from the pressure generating unit as a working fluid for hydraulic preforming of the sheet. Contact faces of the tools directly engage with the sheet surface along the clamping area thereof and act to seal off the forming area that are subjected to the working fluid solely by contact sealing.

Abstract: Apparatus for heat-treating an elongate structural body part made from a blank compressed while being soft or from steel strip of hardenable 22 Mn B5 mod. steel sheet with a thickness of 1 mm to 3 mm, includes an apparatus for positioning the structural body part in substantially upright disposition. Placed in surrounding relationship to the structural body part is an induction element which can move from bottom to top, thereby being able to follow a contour of the structural body part and allowing to at least partially heat the structural body part to an austenitizing temperature suitable for hardening. Disposed adjacent to the induction element is a cooling unit which follows the induction element in movement direction. The induction element and the cooling unit are moveable relative to one another and connected to a tool carriage which is mounted to a column for movement in a vertical direction, in a transverse direction to the column and about a horizontal axis.

Abstract: In a method of manufacturing a bending-resistant, torsionally yielding tubular profiled member as a transverse support of a twist beam rear axle of a passenger car, a tube blank of tempering steel is cold formed to a tubular profiled member with a torsionally yielding central longitudinal section of a U-shaped cross-section and with opposed torsion-proof end sections. At least partial sections of the tubular profiled member are annealed at a temperature level between 850° C. and 960° C. The tubular profiled member is then hardened in water at a temperature above the AC3 point and subsequently tempered at a temperature between 200° C. and 550° C. for a duration of more than five minutes. As an alternative, a tube blank of case hardening steel is used, and at least partial sections of the tubular profiled member formed from this tube blank are case-hardened during a heat treatment with carburization of the surface of the tubular profiled member and subsequent quenching.

Abstract: A twist-beam axle for motor vehicles, includes two longitudinal control arms, and a transverse strut interconnecting the longitudinal control arms and having over a major portion of its length a doubled-walled cross section of V-shaped or U-shaped configuration, thereby defining an inner profile and an outer profile. The inner and outer profiles support one another at least over predetermined portions to define a contact zone therebetween for receiving a friction-reducing additive.

Abstract: A composite control arm shaft for motor vehicles includes two longitudinal control arms connected through a transverse beam, wherein the transverse beam has a trough-shaped double-wall torsion section essentially having the form of a V or U, approximately circular or oval tubular end sections and transition sections whose cross-section continuously changes from the end sections toward the torsion section. The transverse beam has in the transition sections thereof an internal partial foam filling.

Abstract: In a device for hydraulic forming of a tubular component under high inner pressure compressive conditions in a lower die and an upper die of a forming tool, the upper die can be coupled for relative limited movement by at least one piston-cylinder unit containing a hydraulic fluid with the press plunger of a travel-limited mechanical press and the cylinder interior of the piston-cylinder unit can be coupled for providing fluid communication with the interior of the component. Alternatively, in the device for hydraulic forming of a blank under high pressure compressive conditions in a forming tool comprising a lower die and an upper die, the upper die can be coupled for relative limited movement by at least one piston-cylinder unit containing a hydraulic fluid with the press plunger of a travel-limited mechanical press and the cylinder chamber of the piston-cylinder unit can be coupled for establishing fluid communication with the forming space of the forming tool.

Abstract: A twist-beam axle for motor vehicles, includes two longitudinal control arms, and a transverse strut interconnecting the longitudinal control arms and having over a major portion of its length a doubled-walled cross section of V-shaped or U-shaped configuration, thereby defining an inner profile and an outer profile. The inner and outer profiles support one another at least over predetermined portions to define a contact zone therebetween for receiving a friction-reducing additive.

Abstract: In a method for manufacturing elongate structural parts as safety elements for automobile body construction, the structural parts having at least in regions thereof a high strength and a minimum ductility of 5% to 10%, a blank of hardenable steel is shaped in the soft state to form the elongate structural part. The elongate structural part is positioned in an upright position, and an induction element is arranged at the elongate structural part such that it surrounds the elongate structural part and is moveable in the longitudinal direction of the elongate structural part. The elongate structural part is at least partially heated by the induction element to an austenitizing temperature for hardening the elongate structural part by moving the induction element in the longitudinal direction from the bottom to the top of the elongate structural part and by following the contour of the elongate structural part.

Abstract: In a device for hydraulic forming of a tubular component under high inner pressure compressive conditions in a lower die and an upper die of a forming tool, the upper die can be coupled for relative limited movement by at least one piston-cylinder unit containing a hydraulic fluid with the press plunger of a travel-limited mechanical press and the cylinder interior of the piston-cylinder unit can be coupled for providing fluid communication with the interior of the component. Alternatively, in the device for hydraulic forming of a blank under high pressure compressive conditions in a forming tool comprising a lower die and an upper die, the upper die can be coupled for relative limited movement by at least one piston-cylinder unit containing a hydraulic fluid with the press plunger of a travel-limited mechanical press and the cylinder chamber of the piston-cylinder unit can be coupled for establishing fluid communication with the forming space of the forming tool.