Abstract: A fuel distributor, in particular a fuel distribution rail for mixture-compressing, spark-ignited internal combustion engines, includes a base body at which at least one high-pressure input and multiple high-pressure outputs are provided and at least one insert element which is situated in the base body, the insert element separating a distribution area which connects the high-pressure outputs to one another at least essentially from a damping area. The insert element is configured at least essentially as a reshaped insert element. The insert element forms a divider which separates the distribution area at least essentially from the damping area. Furthermore, a fuel injection system including such a fuel distributor is provided.

Abstract: A heat exchanger for a motor vehicle comprises a fluid reservoir having at least one continuous sidewall. A plurality of first coupling features are formed in a base of the sidewall, wherein the first coupling features are outward extending protrusions. The heat exchanger further comprises a header configured to receive a portion of the fluid reservoir therein. The header includes a mounting tab having a plurality of second coupling features and a plurality of reinforcing features alternately formed therein. Each of the second coupling features are cavities configured to receive a portion of a corresponding one of the first coupling features therein. A receiving surface of each of the second coupling features cooperates with an engaging surface of the corresponding one of the first coupling features.

Abstract: A tub for a container includes an inner tub and an outer tub, each formed of a solid compostable or recyclable sheet formed primarily of plant fiber. Both the inner tub and the outer tub include a floor, a plurality of side walls that are coupled to the floor along common edges and each coupled to two adjacent side walls along common edges, and a rim provided at a top of the side walls. The rim of the inner tub rests on and is secured to the rim of the outer tub such that the side walls of the inner tub extend downwardly into the space between the side walls outer tub, with the side walls of the outer tub surrounding and spaced apart from the side walls of the inner tub. A volume between the side walls of the inner and outer tub provides a cavity.

Abstract: A manufacturing method for a rotor core included in a rotor of a motor punches an electromagnetic steel sheet includes punching a plurality of plates for rotor core from an electromagnetic steel sheet; producing a rotor-core precursor by stacking up the plates for rotor core; manufacturing a rotor core by annealing an outer circumferential region of the rotor-core precursor at a first predetermined temperature, and annealing an inner circumferential region of the rotor-core precursor at a second predetermined temperature; the first predetermined temperature being a temperature at which grain growth of crystals of the electromagnetic steel sheet is promoted; and the second predetermined temperature being a temperature at which grain growth of the crystals of the electromagnetic steel sheet is not promoted.

Abstract: A drive device comprises an electric motor, a first receiving area and a second receiving area. The first receiving area may include converter power electronics. The second receiving area may include further electronics. The first and second receiving areas may be formed on the B-side of the electric motor. The first and second receiving areas may be thermally decoupled from one another by a thermal isolation, such that during the operation of the electric motor a first temperature zone can be formed in the first receiving area and a second temperature zone can be formed in the second receiving area.

Abstract: A low-cost, lightweight telescoping torque tube assembly is reliable, safe, and easy to operate. The assembly has no loose fasteners, and no tools are required to operate the telescoping assembly. The telescoping torque tube assembly has only two parts, namely an end fitting and a torque tube. A resiliently deflectable locking tab is provided on one of the parts, and the locking tab is received by a corresponding locking slot formed in the other part. The locking tab has an abutment edge, and the locking slot has a limit edge facing the abutment edge for engaging the abutment edge when the locking tab is undeflected to prevent axially directed adjustment of the end fitting relative to the torque tube from an extended position toward a retracted position. A user deflects the locking tab to enable adjustment of the end fitting from the extended position to the retracted position.

Abstract: Embodiments of an apparatus that includes a substrate and an inductor residing in the substrate are disclosed. In one embodiment, the inductor is formed as a conductive path that extends from a first terminal to a second terminal. The conductive path has a shape corresponding to a two-dimensional (2D) lobe laid over a three-dimensional (3D) volume. Since the shape of the conductive path corresponds to the 2D lobe laid over a 3D volume, the magnetic field generated by the inductor has magnetic field lines that are predominately destructive outside the inductor and magnetic field lines that are predominately constructive inside the inductor. In this manner, the inductor can maintain a high quality (Q) factor while being placed close to other components.

Abstract: An inner-rotor motor includes a shaft, a rotor magnet, a stator arranged radially outside of and opposite to the rotor magnet, and upper and lower brackets arranged to hold upper and lower bearings. The upper bracket includes an upper cylindrical cover press fitted to an outer circumference of a stator core from above, an upper bearing holding portion configured to hold the upper bearing, and a top plate portion arranged to join the upper cylindrical cover to the upper bearing holding portion. The lower bracket includes a lower cylindrical cover press fitted to the outer circumference of the stator core from below, a lower bearing holding portion arranged to hold the lower bearing, and a bottom plate portion arranged to join the lower cylindrical cover to the lower bearing holding portion. Each of the upper and lower brackets is fixed to the stator core through press fitting.

Abstract: The invention is directed to a dent removing device for removing of dents in ferromagnetic sheet metals by way of inductive heating, said dent removing device comprising a working head with a housing with at least one working face foreseen to be brought in close contact with a dent in a sheet metal and at least one magnetic field generator for generating a magnetic field. According to the invention, the at least one working face comprises a recess for visual control of the dent removing, recess extending at least partially across the at least one working face.

Abstract: A liquid reservoir for use in a microgravity environment includes a bladder for holding a liquid. The bladder includes flexible walls and an opening for extraction of the liquid from the bladder. An internal structure is shaped so as to form a channel to conduct the liquid from an end of the bladder that is distal to the opening. The internal structure is configured to prevent the walls of the bladder from blocking the channel when suction is applied to the opening.

Abstract: A processing station automatically manufactures a cable harness containing a plurality of individual lines. The processing station has a support unit for holding a line bundle containing the individual lines with a predefined, even branched, routing, and a processing unit for the automated fixing of the individual lines of the line bundle to one another. The processing unit has a fixing unit, which is configured for the automated application of a fixing agent to the line bundle. A manipulator is provided for moving the processing unit relative to the line bundle.

Abstract: A torque tube for use in a disk brake system in accordance with various embodiments includes a backleg having a reaction plate and a foot extending axially away from the reaction plate. The torque tube also includes a barrel having a tubular structure having an axis and an inner surface configured to receive the foot.

Abstract: One aspect of the present disclosure relates to an apparatus comprising a first end fitting. The first end fitting comprises a tube engagement portion. The tube engagement portion comprises an outer coupling surface. The outer coupling surface comprises a first virtual cross-section. The first virtual cross-section comprises a first transverse inflection point. Each point along the first virtual cross-section has a first virtual tangent line coplanar with the first virtual cross-section.

Abstract: A method and assembly for forming a rotor include forming a rotor core having a plurality of voids and placing the formed rotor core into a die cavity. The method includes moving a plurality of support shoes to define an outer diameter of the die cavity, and injecting at least one of the plurality of voids with a magnetic slurry. At least one permanent magnet is formed from the magnetic slurry by applying pressure to the rotor core and the magnetic slurry within the die cavity and by applying a magnetic field to align the magnetic slurry. After forming the at least one permanent magnet within the rotor core, the plurality of support shoes are retracted and the rotor core removed with the at least one permanent magnet formed therein.

Abstract: A system and method for electromagnetic surface treatment of a work piece has an electromagnetic pulse generator and an electromagnetic pulse tool. The work piece has a working surface. A current pulse generated by the electromagnetic pulse generator travels through the tool producing an electromagnetic pulse. The electromagnetic pulse interacts with the working surface causing an indentation to form. A residual compressive stress layer is also formed. The indentation has a smooth and continuous topography that is described by an indentation perimeter, an indentation transition region, an indentation sidewall, an impact transition region, and an impact region. The method may also simultaneously, or subsequently, form a second indentation which overlaps with the indentation. An inter-indentation overlap region is formed when the indentations overlap. The inter-indentation overlap region is smooth and continuous. Multiple treated surfaces may easily be formed on the working surface of the work piece.

Abstract: Method for non-destructively forming a component made of cast material beyond the quasistatic elongation at break, wherein the component is formed by means of electromagnetic high-speed forming (EMF) method.

Abstract: A method of welding two workpieces together is described. A conductor in electrical communication with a pulse circuit is provided. A portion of the second workpiece is located adjacent the conductor. The two workpieces are also located together. A portion, or all, of one workpiece is welded to the other by applying a pulse current to one of the workpieces. A method of forming a workpiece is disclosed using a pulse current to move the workpiece into a desired shape.

Abstract: A method of thermomagnetically processing a material includes disposing a workpiece within a bore of a magnet; exposing the workpiece to a magnetic field of at least about 1 Tesla generated by the magnet; and, while exposing the workpiece to the magnetic field, applying heat energy to the workpiece at a plurality of frequencies to achieve spatially-controlled heating of the workpiece. An apparatus for thermomagnetically processing a material comprises: a high field strength magnet having a bore extending therethrough for insertion of a workpiece therein; and an energy source disposed adjacent to an entrance to the bore. The energy source is an emitter of variable frequency heat energy, and the bore comprises a waveguide for propagation of the variable frequency heat energy from the energy source to the workpiece.

Abstract: A tool for modifying a workpiece by either trimming or joining the workpiece. The tool is an electro-hydraulic tool that uses a pulse transmitted through a liquid to trim a workpiece or to join two thicknesses of metal together. A method of trimming the workpiece includes the steps of providing a high voltage discharge in a liquid that drives a workpiece into engagement with a cutting edge of a tool steel insert. A method of joining two or more thicknesses of metal together includes the step of creating a high voltage discharge through an electrode that accelerates one panel or thickness of metal into a second panel that is held stationary by a backing plate while the first thickness of metal is accelerated into the second thickness of metal.

Abstract: Methods are provided for forming/inserting a magnet in a rotor. One method includes coating a plurality of magnetizable particles with a non-metallic material, inserting the coated particles in a rotor, and magnetizing the coated particles. Another method includes inserting a plurality of magnetizable particles into a rotor, submersing the rotor in motor varnish or another viscous, non-metallic material to coat the particles, and magnetizing the particles. Yet another method includes inserting a plurality of magnetizable particles in a rotor, inserting a non-metallic material into the rotor, mixing the particles and non-metallic material to form a mixture, curing the mixture to coat each particle with non-metallic material, and magnetizing the particles.

Abstract: A method of forming a sliding spline-type joint using magnetic pulse forming technology includes providing a female driveshaft member and a splined insert having inwardly formed splines. A male driveshaft member is provided having outwardly formed splines engageable with the insert. A mandrel is provided having outer ribs similar to the outer spline profile of the male driveshaft member. An inductor is provided which is energized to create a pulse magnetic field. The insert is placed over the mandrel. The female driveshaft member is disposed over the insert, and both are placed inside the inductor. The inductor is energized to deform a portion of the female driveshaft member over the insert to form an array of crimps for permanently connecting the female driveshaft member with the insert. The male driveshaft member is engaged into the insert to provide a sliding spline-type of slip joint.

Abstract: A process of manufacturing segments, an anisotropic direction of which is continuously changed in a plane vertically by a uniform magnetic field maintained in a constant direction and a process of arranging a plurality of segments on a circumference, extruding the segments in a ring shape by rheology based on the viscous deformation of the segments, from one thrust-direction end surface of the segments, and subsequently compressing the segments from both thrust-direction end surfaces of the segments are necessarily included. A ring magnet, anisotropy of which is controlled in a continuous direction, is provided, and a source for generating a static magnetic field has energy density (BH) max?160 to 180 kJ/m3.

Abstract: Methods and apparatus for high velocity electromagnetic metal forming are described for sealing containers. The methods include applying an electromagnetic field to the container to seal a metal containing cap to the container. One or more containers may be simultaneously sealed. The apparatus includes an actuator that emits the electromagnetic field to seal the caps to the containers. The containers may contain a medicine.

Abstract: A can manufacturing device in which a tool supporting base has: a plurality of working tool units that support a plurality of working tools; a supporting member that supports a plurality of working tool units; and a linear driving mechanism that reciprocates the working tool units with respect to the supporting member in the axial direction of a workpiece. The linear driving mechanism has: a guide section that is fixed on the supporting member with a base plate therebetween; a slide rail that is fixed on the working tool unit and slides along the guide section; an electromagnetic coil provided on the base plate; a magnet plate that is provided on the working tool unit and generates, between the electromagnetic coil and itself, a thrust force for the guide section; and a supply pipe that is provided at the electromagnetic coil and supplies coolant to the inside of the electromagnetic coil.

Abstract: A method for fixing a boot includes mounting a tubular anchoring areas, defined in opposite ends of a resinous boot, on an outer periphery of a counterpart member, and applying a clamping force to boot bands mounted around respective outer peripheries of the tubular anchoring areas to thereby fix the tubular anchoring areas to the outer periphery of the counterpart member. Coils are disposed around respective outer peripheries of the boot bands to generate an induction current in the boot bands. In this way, a reactive force of the magnetic field is generated between the coils and the boot bands to plastically deform the boot bands and reduce their diameters, whereby the tubular anchoring areas are fixed to the outer periphery of the counterpart member.

Abstract: Electromagnetic forming methods suitable for creating surface features on a shape memory alloy are described. Features may be created over a range of scales, including those suitable for the generation of holographic images. Features, images, or patterns may be made capable of reversibly appearing and disappearing as a result of changes in temperature and may include temperature sensitive displays for automotive and other applications.

Abstract: Methods and devices provide for high velocity forming of medical device casings. The high velocity forming may be produced by creating a pressure wave within a liquid contained by an enclosure. A die and a workpiece adjacent to the die are in the path of the pressure wave within the enclosure and the pressure wave forces the workpiece to conform to the contours of the die. Objects may be adhered to the die to provide for customized contours. Trimming features may be included within the enclosure to trim excess material from a formed workpiece as an integral part of the forming process. Various other features may also be provided within the enclosure including a diffuser to disperse the pressure wave. The workpiece may be of various forms including flat sheet stock.

Abstract: Articles are often formed from a tubular workpiece in a process which does not usefully shape the ends of the tube. In an embodiment of the invention, tube ends may be mechanically reduced in cross section and then expanded against a secondary forming surface(s) using an electromagnetic force to obtain desired shapes for the tube ends and minimize scrapping of workpiece material.

Abstract: A method for assembling a motor vehicle axle including suspension arms and a cross-member mounted between the arms. The method applys an adhesive element on at least one portion of the cross-member, mounts the portion inside a bore of one of the suspension arms to as to leave a clearance between the suspension arm and the adhesive element, and radially deforms one of the assembling elements of the cross-member and the suspension arm to obtain a contact between the adhesive element and the bore of the suspension arm.

Abstract: An electromagnetically formed fluid circuit joint (150) includes a tubular conduit (58) that has an outer surface (154) with a groove (72). A hollow fitting (56) is mechanically separate from and received over the tubular conduit (58). The hollow fitting (56) includes an electromagnetic field formed wall deformation (165) that extends into the groove (72).

Abstract: A method is provided for manufacturing a shaped tubular part from a first tube and second tube. The end of the first tube is inserted into the end of the second tube to provide a region of overlapping tube walls. An induction coil is placed around the outer surface of the first and second tubes at the region of overlapped tube walls. The induction coil is energized to make a plurality of longitudinally spaced apart magnetic pulse welds attaching the tubes together to thereby form a multi-tube one-piece composite tubular assembly. The tubular assembly is then subjected to a forming process such as hydroforming, tube bending or stretch bending to form the final shape of the tubular part.

Abstract: A method of using an electromagnetic forming machine to hem a panel assembly includes providing an inner panel and an outer panel. The outer panel has a plurality of flanges and a plurality of relief areas. An electric forming machine is provided having a coil for discharging electric energy to generate a magnetic field. The inner panel is positioned such that portions of the outer edge of the inner panel are aligned with the flanges of the outer panel to form a loose assembly of panels. The loose assembly of panels is positioned proximate the electromagnetic forming machine such that the coil surrounds the flanges and is disposed substantially coplanar with a plane formed by the relief areas. The electromagnetic forming machine is activated to generate a magnetic field causing the flanges to bend over.

Abstract: A tubular preform is contracted in an electro-hydraulic forming operation. The tubular preform is wrapped with one or more coils of wire and placed in a chamber of an electro-hydraulic forming tool. The electro-hydraulic forming tool is discharged to form a compressed area on a portion of the tube. The tube is then placed in a hydroforming tool that expands the tubular preform to form a part.

Abstract: A method prevents a cylindrical body from buckling in externally curling edges of both side portions by pressing curling dies in an axial direction after molding the cylindrical body having a drop portion whose outer diameter is small and two side portions whose outer diameter is large by enlarging a cylindrical material made of aluminum alloy by electromagnetic molding. In curling the edges of the side portions, a buckling preventing die restrains an outer periphery of the drop portion of the cylindrical body. Because the buckling preventing die receives the axial compression force of the curling dies, it can prevent the cylindrical body from buckling and deforming. The buckling preventing die is what a split die disposed on the side of an outer periphery of the cylindrical material in the electromagnetic molding is used as.

Abstract: A method of making a motor stator core having a back iron and a plurality of teeth extending radially inward from the back iron includes providing the plurality of teeth and the back iron from oriented steel so that a magnetic flux transmission path is formed with superior properties in essentially one direction. At least one of the plurality of teeth and the back iron is annealed in selected portions so as to improve magnetic flux transmission in a second direction, different from the one direction.

Abstract: A vehicle exhaust system is provided that includes a first exhaust member having an end that includes an enlarged section. A second exhaust member is sized to receive a portion of the first exhaust member. The enlarged section of the first exhaust member has an outer diameter that is larger than an inner diameter of at least one section of the second exhaust member for creating an interference condition between the first and second exhaust member to prevent axial movement of the first exhaust member in at least one axial direction. The first exhaust member is secured to the second exhaust member by magnetic pulse welding.

Abstract: An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die.

Abstract: The present invention provides a linear motor mounted press machine that generate an optimum thrust for a press tonnage to perform different machining operations including one requiring a greater press tonnage and one requiring a high speed and a smaller press tonnage in an energy efficient manner. A linear motor mounted press machine includes a first linear motor 11, a second linear motor 12 that produces a thrust lower than or equivalent to that of the first linear motor 11, and a coupling switching mechanism 13 that releasably couples output shafts 30, 34 of the first and second linear motor 11, 12 together. A press tool 6 is driven forward and backward by the output shaft 34 of the second linear motor 12. Each of first and second linear motors 11, 12 is a unit linear motor assembly having a plurality of unit linear motors 15 arranged around a press working axis center P. The number of the unit linear motors 15 of the second linear motor 12 is the same as or smaller than that of the first linear motor 11.

Abstract: A device for producing a patterned plate from a tubular work piece is disclosed wherein walls of the tubular work piece comprise at least one forming surface. The device comprises a die and an electromagnetic actuator, wherein the die comprises a patterned surface with a pattern formed thereon and a fracturing part. The tubular work piece is disposed between the die and the electromagnetic actuator such that the walls of the tubular work piece correspond to walls of the die, and the forming surface corresponds to the patterned surface. When the electromagnetic actuator is supplied with a current pulse, an eddy current is induced in the tubular work piece, generating a repulsive force between the electromagnetic actuator and the tubular work piece. Therefore, the tubular work piece impacts the die, and the forming surface is deformed against the patterned surface and the fracturing part, thus replicating the pattern of the patterned surface onto the forming surface.

Abstract: Methods are provided for forming/inserting a magnet in a rotor. One method includes coating a plurality of magnetizable particles with a non-metallic material, inserting the coated particles in a rotor, and magnetizing the coated particles. Another method includes inserting a plurality of magnetizable particles into a rotor, submersing the rotor in motor varnish to coat the particles with motor varnish, and magnetizing the particles. Yet another method includes inserting a plurality of magnetizable particles in a rotor, inserting a non-metallic material into the rotor, mixing the particles and non-metallic material to form a mixture, curing the mixture to coat each particle with non-metallic material, and magnetizing the particles. Still another method includes mixing a plurality of magnetizable particles with a non-metallic material, curing the non-metallic material to coat each particle with non-metallic material, inserting the coated particles in a rotor, and magnetizing the coated particles.

Abstract: A method for manufacturing a ferrite magnet device including a ferrite body and first and second center electrodes arranged so as to intersect and be electrically insulated from each other and a permanent magnet arranged to apply a direct current magnetic field to the ferrite body and a method for manufacturing an isolator or a composite electronic component, which include the ferrite magnet device. A magnetic force of the permanent magnet is adjusted using a measurement jig and a magnetic force adjusting apparatus while the permanent magnet is fixed to a principal surface of the ferrite body.

Abstract: Process for fabricating an axle that includes a cross-member and arms which are assembled to extremities of the cross-member, wherein the process includes forming a cross-member, forming at least one arm, arranging the cross-member and the at least one arm in a fastening position, and fastening together in a rigid manner the cross-member and the at least one arm using a magneto-forming process. Wherein the fastening occurs while the cross-member and the at least one arm are in the fastening position and at least one of the cross-member and the at least one arm include at least one metallic material. This abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

Abstract: An electrohydraulic forming (EHF) tool having a pair of electrodes that can be used to generate a shockwave to facilitate forming a sheet metal blank against a forming die. The electrodes may be adjusted during the course of operation. This may be useful should continued use cause their efficiency to drop below a desired threshold.

Abstract: A multi-layer driver plate is disclosed for use in electromagnetic sheet metal forming operations. In one embodiment, the driver plate comprises a first layer characterized by low electrical resistivity and thickness for inducement and application of a suitable electromagnetic forming force, a second layer comprising an elastomeric material for compressing a sheet metal workpiece against a die surface and then regaining its original pre-forming structure, and a third layer interposed between the first layer and the second layer to protect the EMF force providing layer and to provide overall strength and durability to the EMF driver plate.

Abstract: A magnetic forming system (10) for creating a fluid circuit joint between a tube and a fitting includes an induction coil (12). The induction coil (12) may form a first stage electromagnetic current. A field concentrator (132) may focus the first stage electromagnetic current to form a second stage electromagnetic current. An insert (136) may focus the second stage electromagnetic current to form an electromagnetic field. The electromagnetic field forms the fluid circuit joint. The induction coil (12) may be insertable within the tube, generate an electromagnetic field, and impose the electromagnetic field on and to expand a portion of the tube within the fitting to form the fluid circuit joint. The system (10) may include a receptacle (54) that is external to the tube and the fitting. An insert (56) may be mechanically coupled within the receptacle (54) and limit the outward expansion of the tube and the fitting.

Abstract: A metal mold is disposed adjacent to the outer circumference of a base ring, and has a molding face in the inner circumference and a plurality of grooves for forming beads on the molding face along the circumferential direction. A coil for electromagnetic forming is disposed adjacent to the inner circumference of the base ring. When a momentary large current is applied to the coil in this arrangement, the diameter of the base ring is expanded by pressing the base ring toward the molding face of the metal mold such that the base ring is molded into a shape corresponding to the molding face by electromagnetic forming. Improvements such as a metal mold capable of degassing, a separable metal mold, roll-correcting after electromagnetic forming, application of momentary large current over several times, a metal mold with a cutting blade, use of a base ring with a large number of holes, and a metal mold with positioning means are then added.

Abstract: An apparatus for electromagnetically forming a workpiece. The apparatus includes a solenoid coil for generating an electromagnetic force and a tool for concentrating electromagnetic force against the workpiece. The tool includes an electrically conductive body having an aperture and an insulator disposed in the aperture.

Abstract: A metal mold for electromagnetic forming, with the inner peripheral face thereof, serving as a forming face, is disposed on the outer peripheral side of a columnar workpiece, and a coil for electromagnetic forming is disposed on the inner peripheral side of the columnar workpiece. In a state of a configuration as described, electric energy is thrown into the coil for the electromagnetic forming, and the columnar workpiece is caused to undergo flaring to be thereby pressed against the forming face of the metal mold for the electromagnetic forming, so as to be turned into a shape corresponding to the forming face by means of the electromagnetic forming, thus obtaining a wheel rim. A disc is welded to the wheel rim obtained, and curling is applied to outer edges of the wheel rim. With the adoption of a method of manufacturing an automotive wheel, a manufacturing process as a whole is enhanced in efficiency.

Abstract: A method is provided for manufacturing a shaped tubular part from a first tube and second tube. The end of the first tube is inserted into the end of the second tube to provide a region of overlapping tube walls. An induction coil is placed around the outer surface of the first and second tubes at the region of overlapped tube walls. The induction coil is energized to make a plurality of longitudinally spaced apart magnetic pulse welds attaching the tubes together to thereby form a multi-tube one-piece composite tubular assembly. The tubular assembly is then subjected to a forming process such as hydroforming, tube bending or stretch bending to form the final shape of the tubular part.

Abstract: A method of forming a torque-transmitting coupling (193) includes forming at least one fitting (192) having a tube conforming area (200). The forming area (200) includes a material overflow groove (194) and multiple flat surfaces (202). The forming area (200) has an associated tube arc length that is approximately equal in length to a formed area length of the flat surfaces (202) with the elongated overflow groove (194). An elongated tube (190) is procured. The elongated tube (190) is formed onto the tube conforming area (200) to form the torque-transmitting coupling (193).