Abstract: A device for forming a hollow profile formed as a multi-chamber profile (21) by means of an internal high pressure generated by a fluid pressure medium within the hollow profile containing a sealing die (1a) engaging in the profile chamber (20) with a carrier part (3a) and a collar (2a) arranged on the carrier part (3a) sealing the face side of the profile chamber (20). The die (1a) also has a passage opening (7a) as a pressure medium supply and/or extraction channel (9a). The collar (2a) is a resilient rubber die part arranged on the face of the carrier part (3a) facing the profile chamber (20) and on the free face (16a) of the collar (2a) is provided a preload plate (6a) which is anchored by way of the fixing means (8a) penetrating the collar (2a) in the carrier part (3a) lying on the collar (2a) so that the collar (2a) is squeeze-clamped between the preload plate (6a) and the carrier part (3a).

Abstract: In the present invention, in a method of fabricating a metal vessel formed by expanding in hydraulic bulge formation a cylinder having a bottom, wherein a flat plate material is formed into a cylinder, the edges welded, and a bottom member welded to one open part of the cylindrical shell member, the stationary point of the expanded part of the shell member is made the expanding part side from the shell member—bottom member weld of the cylinder with a bottom, and thereby by expanding the shell part on the opening side, a metal vessel is formed, and thus the time of the processing itself of a plurality of expanding process of press-working and ironing and transiting of moving from one step to the next can be completed by one step, decreasing the time and reducing the cost.

Abstract: The invention relates to a method and apparatus for the production of double-walled hollow sections by means of internal high-pressure forming, a first hollow section being inserted into a second hollow section, after which the double-walled hollow section thus formed is subjected to high internal fluid pressure in such a way in an internal high-pressure forming die that the double-walled hollow section is expanded. During this process, an air gap is formed between the first, inner, hollow section and the second, outer, hollow section.

Abstract: A forming device having a fluid source for providing a pressurized fluid, a strongback having a die cavity, a tubular workpiece having a hollow interior, a die and a mandrel assembly. The die is formed from a plurality of mated die components and includes an internal cavity which is configured to correspond to a predetermined tube profile. The die is at least partially disposed in the die cavity and surrounds at least a portion of the tubular workpiece. The mandrel assembly is disposed at least partially within the hollow interior of the tubular workpiece in an area proximate the die and is in sealing engagement with the hollow interior of the tubular workpiece. The mandrel assembly includes at least one feed aperture that is in fluid connection with the fluid source. The feed aperture directs the pressurized fluid against the hollow interior of the tubular workpiece to cause the tubular workpiece to expand into the internal cavity.

Abstract: A method and a device for manufacturing a hollow body from two plates, which are placed against one another and inserted into an internal high pressure forming tool. After the forming tool is closed, a fluid is introduced under high pressure between the plates by way of an expansion lance inserted between the plates. The plates are expanded until they abut the interior surfaces of the forming tool that match the shape of the hollow body. To achieve a process-reliable manufacture of the hollow body, the plates, before any internal high pressure is developed, are pinched in the thickness direction along the circumference of the opening that surrounds the inserted expansion lance by cooperation between the dies of the forming tool and the circumferential contour of the expansion lance that is oversize relative to the location between the plates at which the expansion lance is introduced.

Abstract: A blank with a closed profile is made of hardenable sheet steel and is hydroformed when hot. The tool is cooled and the blank is heated to a hardening temperature and formed so fast that it will not have time to harden before it contacts the tool and becomes rapidly cooled by the tool and by the liquid fluid so that it hardens. In this simple way, a product of high strength steel can be achieved which has a closed profile and complicated form. The product can be, for example, a bow-formed bumper.

Abstract: A mechanical press is adapted to perform a hydroforming operation. The press includes a stationary base supporting a bolster that carries a lower die section, a movable slide that carries an upper die section, and a drive mechanism for selectively raising and lowering the slide relative to the base. An inflatable bladder is disposed between the base and the bolster. Initially, the drive mechanism is operated to lower the slide to its bottom dead center position such that the die sections enclose a workpiece within a die cavity. Then, pressurized fluid is supplied within the workpiece to expand it outwardly into conformance with the die cavity. At the same time, pressurized fluid is also supplied to the interior of the inflatable bladder. The application of such pressurized fluid causes the inflatable bladder to be physically expanded, causing the bolster carrying the lower die section to be raised relative to the base.

Abstract: The invention concerns an engraved surface of a deformation tool which deforms a workpiece with an active medium, wherein the deformation tool has a pressure agent feed for the active medium and an engraved surface according to the desired final contour of the workpiece. Accordingly deformation methods are performed with hydro-deforming as well as of internal high-pressure metal forming of a wall of a workpiece by the engraved surface of the tool by way of the pressure medium. Upon withdrawal of the workpiece the pressure medium can pass to the engraved surface of the tool, during the deformation of the following workpiece no contact between the engraved surface and the workpiece wall occurs due to the pressure agent adhering to the engraved surface, whereby undesired deformations occur on the workpiece.

Abstract: The invention relates to a process and an apparatus for the internal high-pressure forming of a workpiece in a closed internal high-pressure forming die. In the present invention, the workpiece is expanded by a fluidic internal high pressure exerted by a pressure generator and the workpiece is brought to bear against the cavity of the forming die. To improve the process reliability during the internal high-pressure forming of the workpiece, it is proposed to introduce the internal high pressure in the form of a pressure oscillation.

Abstract: A space frame includes a pair of laterally spaced, longitudinally extending side rail structures and longitudinally spaced pairs of laterally spaced upright structures having joints at their lower ends with the pair of side rail structures. The longitudinal spaced pairs of laterally spaced upright structures extend upwardly from the side rails structures and define a plurality of pairs of pillars, including a pair of forward A pillars, a longitudinally spaced pair of B pillars, and a longitudinally spaced pair of rearward end pillars. A pair of the side roof structures has joints with the pair of A pillars. The pair of side roof structures extends longitudinally rearwardly from the pair of A pillars and have joints with the pair of B pillars and with the pair of rearward end pillars. Longitudinally spaced cross structures have joints with the pair of side rail structures, with the pair of A pillars and with the pair of side roof structures.

Abstract: A method and apparatus for sealing the net shape of the end of a final product tube to eliminate or minimize scrap for a wide range of shapes of the end of the product. A sealing tool has a neck, and a coining portion comprising a shoulder extending outwardly from the neck. The sealing tool is inserted into the deformed end of the tube while the end is being laterally engaged by a clamp pressing inwardly against the outer surface of the tube. The end is then sealed by coining a surface of the tube by axially pressing the sealing tool into the end while laterally inwardly pressing the end with the clamp.

Abstract: A blow molding method for use with tubular metal work pieces. The method involves placing a tubular metal component part into a molding tool having an internal molding cavity and at least one access passageway into which the component is inserted. The molding tool is then heated to a temperature between about 1000° F. and 1200° F. and a high pressure gas is injected into the tubular component. The high pressure gas causes the portion of the work component residing within the internal mold cavity of the molding tool to expand and assume the shape of the internal molding cavity. After a cooling period, the component is removed from the molding tool. The process is particularly well suited for forming the end support portions of side rails used with vehicle article carriers, but can be used to form a wide variety of complexly shaped forms from tubular metal workpieces.

Abstract: A nozzle to be used for hydrostatic forming, through which pressurized fluid is supplied into a tube located inside a die. The nozzle comprising a fitting section integrally connected to a base section and insertable into an end section of the tube so as to be fitted in the tube. The fitting section has an opening through which the pressurized fluid is ejected to be supplied into the tube. The fitting section has a generally rectangular cross-section in a place perpendicular to an axis of the nozzle.

Abstract: A method and apparatus for reshaping a container body (e.g., a metal, drawn and ironed container body) utilizing a floating mechanism for imparting an axial load is disclosed. In one embodiment, a container may have a substantially cylindrical sidewall with an inner surface and outer surface, where a shape defining means has a contoured surface positionable with respect to a container sidewall. When a floating mechanism imparts an axial load, a fluid seal is maintained allowing sidewall deformation by means of a directed pressurized fluid.

Abstract: A molding method uses a fluid-pressure generating unit form generating high fluid pressures that allows high-precision molding of complex shapes. The high fluid pressure is generated with a piston disposed in communication with a molding cavity. The high fluid pressure is imposed on a raw material workpiece to push the workpiece into a cavity causing the workpiece to conform to the shape of the cavity thereby producing an article of desired shape.

Abstract: The invention concerns a method of producing a hollow profile with flange. To produce a hollow profile with flange in a simple way and to the requirements of the process, on which profile great enlargements and/or dimensional changes in cross section have to be performed with respect to an initial form to achieve the desired final form, it is proposed first of all to roll-form an initial hollow profile with flange from a sheet bar, which flange is formed by ends of the sheet bar lying parallel against each other, the initial hollow profile having a smaller cross-sectional area and a longer flange than the final form of the hollow profile. After that, the initial hollow profile is shaped into the final form of the hollow profile by exerting a fluidic internal high pressure.

Abstract: For shaping small radii in edge and corner regions of preformed workpieces or blanks, the invention provides for a postforming of exclusively said edge and corner regions by high liquid pressure. For performing the method an apparatus has a die part (forming insert) with expansion spaces constructed in its edge and corner regions.

Abstract: A method for hydroforming a metallic tube comprising primary hydroforming and secondary hydroforming, wherein in the primary hydroforming step, the metallic tube is formed such that a circumferential length of an expanded portion of the primary-hydroformed tube as measured at a wall center region of the expanded portion becomes substantially equal to or slightly shorter than a circumferential length of an expanded portion of a product as measured at a wall center region of the expanded portion, and in the secondary hydroforming step, movable forming plates incorporated in the dies press the expanded portion formed through primary hydroforming so as to finish the cross-sectional profile of the expanded portion into that of the expanded portion of the product, and said primary hydroforming and secondary hydroforming are continuously performed within the dies. Also disclosed is an apparatus for performing the hydroformation method.

Abstract: In the present invention, in a method of fabricating a metal vessel formed by expanding in hydraulic bulge formation a cylinder having a bottom, wherein a flat plate material is formed into a cylinder, the edges welded, and a bottom member welded to one open part of the cylindrical shell member, the stationary point of the expanded part of the shell member is made the expanding part side from the shell member—bottom member weld of the cylinder with a bottom, and thereby by expanding the shell part on the opening side, a metal vessel is formed, and thus the time of the processing itself of a plurality of expanding process of press-working and ironing and transiting of moving from one step to the next can be completed by one step, decreasing the time and reducing the cost.

Abstract: Tubular members for use in vehicle frames are easily and economically produced using a hydroforming process in which a high pressure fluid is presented to the interior of a tubular member, thus causing the tube to expand to meet the interior walls of a forming die. Tubular members can be formed having significant variations in their circumference, diameter along their lengths, or gage along their lengths by using a stamped blank having a predetermined shape which is formed into a preformed tube which roughly mirrors the shape of the desired finished tubular member.

Abstract: In the present invention, in a method of fabricating a metal vessel formed by expanding in hydraulic bulge formation a cylinder having a bottom, wherein a flat plate material is formed into a cylinder, the edges welded, and a bottom member welded to one open part of the cylindrical shell member, the stationary point of the expanded part of the shell member is made the expanding part side from the shell member—bottom member weld of the cylinder with a bottom, and thereby by expanding the shell part on the opening side, a metal vessel is formed, and thus the time of the processing itself of a plurality of expanding process of press-working and ironing and transiting of moving from one step to the next can be completed by one step, decreasing the time and reducing the cost.

Abstract: A tubular plate is formed for a wiper device as a support for at least one wiper bearing and a wiper drive, with tubular members for receiving a wiper bearing. The tubular plate is deformed without removal of a material, has tubular members for receiving the wiper drive, and the tubular members are formed on the tubular plate of one piece with it.

Abstract: A hydroforming apparatus for simultaneously performing two or more hydroforming operations includes a frame that is sized to support a plurality of hydroforming dies in a stacked relationship. Each of the dies includes a pair of cooperating die sections having respective recesses formed therein that define a die cavity. Initially, the first die section of the first die is positioned in an uppermost spaced apart position relative to the second die section of the second die, while the second die section of the first die and the first die section of the second die are positioned in an intermediate spaced apart position relative to both the first die sect of the first die and the second die section of the second die. Then, hollow tubular blanks are inserted between the spaced apart die sections of the first and second die Next, the ram and the support mechanism are moved downwardly relative to the be such that the pairs of cooperating die sections of the first and second dies engage one another.

Abstract: An apparatus is provided for forming a tubular fitting from a blank tube having an interior. The apparatus includes a right die plate, a left die plate, a lower die plate and an upper die plate. The right die plate has a first cavity capable of receiving the blank tube. The left die plate has a second cavity aligned with the first cavity. The right die plate has a first guide post and the left die plate has a second guide post. The first cavity is joined to the second cavity to form a forming cavity. The lower die plate is capable of supporting the right die plate and the left die plate. The lower die plate includes a port capable of receiving a fluid line. The upper die plate is capable of moving between a first position and a second position. The upper die plate has guide holes for receiving the first and second guide posts and aligning the upper die plate with the right die plate and the left die plate.

Abstract: A process for hydroforming an elongate tubular structural member in a mould die, the structural member having portions spaced along its length which have different circumferential dimensions, a first of said portions having a first cross-sectional shape defining a minimum outer circumferential dimension C.sub.1 and a second of said portions having a second cross-sectional shape defining a maximum outer circumferential dimension C.sub.2, the process including the steps of: (i) selecting a precursor tube of constant cross-sectional shape and constant outer cross-sectional dimension along its length and having an outer circumferential dimension C.sub.0 which is greater than or equal to C.sub.1 and being of a cross-sectional shape which can be located within said first cross-sectional shape, and selecting the wall thickness S.sub.0 of the precursor tube so as to fall within the range S.sub.0 .ltoreq.S.sub.1 and S.sub.0 .gtoreq.S.sub.2 wherein S.sub.

Abstract: A method and apparatus for providing a contoured design confirguration in the wall of an open ended container workpiece employs plural molds on a rotating turret an which a plurality of molds are provided with each mold having an inwardly facing wall having the desired configuration. The workpiece is delivered from a pneumatic conveyor and vacuum star wheel into an open mold which then closes and the interior of the workpiece is pressurized with air. A rotary wand moves into the workpiece and discharges high velocity rotating liquid jets against the inner wall surface of the workpiece to forcefully move the wall outwardly into conforming contact with the inner wall surface of the mold to effect permanent reshaping of the workpiece into the desired configuration.

Abstract: A mold is provided having a mold cavity in the final shape of an article and a hollow article is placed in the mold adjacent the mold cavity. The hollow article is preformed into an intermediate shape by closing the mold around the hollow article, and then formed into the final shape by introducing fluid pressure into the preformed hollow article to conform the preformed hollow article into the shape of the mold cavity.

Abstract: A bulging device and a bulging method for bulging a workpiece into an accurate shape, and preventing the generation of cracks therein. High pressure liquid is supplied to the interior space of a workpiece and from an external pressure supply mechanism to the outer space of the workpiece in cavity. An internal pressure detection sensor or an external pressure detection sensor is controlled according to the detected pressure, thereby controlling the pressure of the interior space of the workpiece or the pressure of the outer space of the workpiece in the cavity. Alternatively, position sensors for detecting displacement of pushing dies are provided such that the pressure of the interior space of the workpiece or the pressure of the outer space of the workpiece in the cavity is controlled according to the detected displacement.

Abstract: A method for manufacturing a non-driving, rigid axle beam for use in a vehicle frame and suspension system includes the initial step of providing a tubular blank. The tubular blank is disposed within a die having cooperating die sections that define a cavity having a shape that corresponds with the desired shape of the non-driving axle beam. Next, pressurized fluid is provided within the tubular blank so as to deform the tubular blank into conformance with the die cavity. A steering knuckle can be pivotably connected to each end of the non-driving axle beam by securing a hollow cylindrical support to each end of the non-driving axle beam and pivotably connecting a steering knuckle to each end of the hollow cylindrical supports. The non-driving axle beam can be formed having any desired cross sectional shape, including circular, triangular, I-shaped, and oval.

Abstract: The invention relates to a method for shaping a hollow body from a tubular blank inserted into a shaping tool that can be opened and closed, by internal high pressure introduced into the interior of the blank. The cross section of the blank, prior to the internal high-pressure shaping, can be changed and pre-shaped from a round or rectangular shape, depending on the workpiece. In order to be able to produce workpieces with a circumference that varies considerably over the length without overstretching the material, according to the invention, for pre-shaping the blank, a dent that differs in depth over its length is formed in the blank. During the internal high-pressure shaping of the pre-shaped blank to form a hollow body, a U-shaped fold is formed from the dent that projects into the interior of the hollow body, with the walls of the fold abutting one another directly and merging at the periphery with the circumferential wall of the hollow body.

Abstract: A method for hydroforming a metallic tube comprising primary hydroforming and secondary hydroforming, wherein in the primary hydroforming step, the metallic tube is formed such that a circumferential length of an expanded portion of the primary-hydroformed tube as measured at a wall center region of the expanded portion becomes substantially equal to or slightly shorter than a circumferential length of an expanded portion of a product as measured at a wall center region of the expanded portion, and in the secondary hydroforming step, movable pads incorporated in the dies press the expanded portion formed through primary hydroforming so as to finish the cross-sectional profile of the expanded portion into that of the expanded portion of the product, and said primary hydroforming and secondary hydroforming are continuously performed within the dies. Also disclosed is an apparatus for performing the hydroformation method.

Abstract: A hydroformed control arm for a vehicle and a method of making the same is provided. The control arm includes a generally U-shaped member being hydroformed from a continuous, unitary tube. The generally U-shaped member includes varying cross-sectional areas along its length for improved structural integrity. The generally U-shaped member further includes a pair of pivot bores for enabling the control arm to pivot about a pivot axis. The U-shaped member still further including a ball joint cavity disposed near its apex for receiving a ball joint. The hydroformed control arm thereby eliminates the need for a ball joint bushing.

Abstract: A process for superplastically forming a tube of superplastic material to make a part includes sealing both ends of the tube with end caps to provide a sealed enclosed volume within the tube. At least one of the end caps has a connection that communicates between the enclosed volume and a gas line for connection to a gas management system for controlling forming gas pressure inside the enclosed space. The tube is inserting in a die and the connection is coupled to a gas supply line from said gas management system for supplying forming gas under pressure to said enclosed volume. The die and the tube are heated to the superplastic forming temperature for said material, and gas is introduced from the gas management system for pressurizing the enclosed volume with pressurized forming gas and for expanding the tube against the internal surfaces of the die.

Abstract: A method and apparatus for reshaping a container body (e.g., a metal, drawn and ironed container body) utilizing a floating mechanism for imparting an axial load is disclosed. In one embodiment, a container may have a substantially cylindrical sidewall with an inner surface and outer surface, where a shape defining means has a contoured surface positionable with respect to a container sidewall.When a floating mechanism imparts an axial load, a fluid seal is maintained allowing sidewall deformation by means of a directed pressurized fluid.

Abstract: A vehicle suspension control arm (10) is formed as a single, homogeneous unit of metal material in the configuration of an elongated tube (30). The tube (30) has first and second pairs of opposed openings (68, 68; 80, 80) defining first and second passages (72, 82) which are sized to receive first and second pivotal joint structures (20, 22), respectively. The first and second passages (72, 82) extend transversely through first and second hydroformed sections (40, 42) of the tube (30).

Abstract: A vehicle part suitable to form a part of a rigid vehicle assembly, such as a vehicle frame assembly or the like. The vehicle part is formed from a cylindrical blank having a predetermined wall thickness and a predetermined peripheral dimension. The cylindrical blank is bent and hydroformed to provide a tubular wall having a central bend therein of at least approximately 30.degree. and opposite angularly related end portions. The central bend has a peripheral dimension in excess of approximately 10% of the predetermined peripheral dimension of the cylindrical blank. The central bend includes a concave portion free of wrinkles and a convex portion having a wall thickness within plus or minus 10% of the predetermined wall thickness of the cylindrical blank.

Abstract: A method for hydroforming a large surface area, double paneled, hollow auto body part, such as a hood, in which the inner and outer panels are concurrently shape formed and seamed structurally together in the same apparatus. A pair of upper and lower dies crush the edges of a double walled blank together between the dies so as to simultaneously clamp, seal, and form the seam. Then, a special face seal and fluid inlet assembly grips and holds the edges of an inlet hole near the center of the blank to allow the interior to be successfully pressurized and expanded.

Abstract: The invention is directed to a forming device, especially internal high-pressure forming device, with a multiple-part forming tool and a clamping device which holds the parts of the forming tool together against the deforming action. In the novel forming device, according to the invention, the clamping device and/or the forming tool have/has at least one counter-clamping device which compensates at least partially for deformations of the mold cavity during forming. The possibility of compensation according to the invention makes it possible to construct the clamping and/or forming tool parts in a less solid manner.

Abstract: An apparatus for hydraulically shaping hollow bodies of metal using a shaping tool arranged in a press frame includes a shaping tool arranged in a press frame, wherein the shaping tool has a lower part mounted so as to be displaceable vertically guided between an open position and a closed position and a movably supported upper part, wherein the lower part can be locked in the closed position by a locking member and the upper part can be pressed hydraulically against the lower part.

Abstract: A method for hydroforming a closed channel structural member that allows the perimeter to be increased, but which maintains a relatively uniform wall thickness throughout, includes the initial step of disposing a closed channel structural member, such as a tube, within a first hydroforming die defining a first die cavity. The inner surface of the first die cavity corresponds in cross sectional shape to the outer surface of the tube, but the perimeter of the first die cavity is somewhat larger than the perimeter of the tube enclosed therein. A preliminary hydroforming operation is then performed at a relatively high pressure to expand the tube into conformance with the first die cavity. Throughout most of this expansion, the outer surface of the tube does not engage the inner surface of the die cavity. As a result, as the perimeter of the tube is increase, the wall thickness thereof is decreased uniformly.

Abstract: An apparatus for hydroforming a tubular metal blank comprises a die structure, a hydroforming fluid source, a hydraulically driven tube-end engaging structure, a hydraulically driven pressure intensifying structure, and a single hydraulic power source. The tube-end engaging structure seals opposite ends of the tubular metal blank in said die cavity and is movable to longitudinally compress the tubular metal blank. The tube-end engaging structure receives hydroforming fluid from said hydroforming fluid source and has a hydroforming fluid supplying outlet through which hydroforming fluid can be provided to the tubular metal blank. The hydraulically driven pressure intensifying structure is movable to pressurize the hydroforming fluid provided to the interior of the tubular metal blank and thereby expand a diameter of the blank.

Abstract: A vehicle side door or hatchback structure incorporates at least one hydroformed component. In one configuration, a window frame, a door frame and a reinforcement member are press-fit together by pressurized fluid during a hydroforming process to join the frames and the reinforcement member together. In another configuration, a vehicle hatchback frame subassembly includes a one-piece hydroformed window frame with a central portion disposed between opposing end portions. Inner and outer panels are attached to each other and secured to the opposing end portions of the window frame. In yet another configuration, a vehicle door and window frame subassembly includes a hydroformed one-piece first door frame, a roll formed second door frame and a reinforcement member secured to the tubular one-piece first door frame. An outer front panel is attached to the reinforcement member by at least one mirror bracket.

Abstract: An arrangement for the internal high-pressure forming of hollow profiles has an internal high-pressure forming tool, into whose die sinking the hollow profile can be inserted. At least one axial die has a sealing head which can be inserted with play by a section into the hollow profile. This sealing head has a support part which is provided with a pressure fluid duct and on which a sealing arrangement is held and which is rigidly connected with the axial die, and has a stop surface, which in the operative position of the sealing head rests on the face side against the end of the hollow profile. The sealing arrangement contains at least one sealing element which can be radially spread open for an allaround sealing contact on the interior side of the hollow profile.

Abstract: The invention relates to a process and apparatus for manufacturing hollow sections with cross-sectional expansions in end portions thereof. A hollow blank is widened and calibrated by internal high pressure forming by means of a forming tool receiving it, and, after the calibration, is separated in the area of the widening while forming two hollow sections with cross-sectionally widened ends facing one another in the separated position. In order manufacture from a hollow blank hollow sections with the lowest possible reject rate and therefore in a reliable process, which are cross-sectionally widened on the end side by means of high degree for forming, the blank is widened while the forming tool is open and is simultaneously upset to form a rotationally symmetrical bulging hollow section by means of a pressure force which is axially directed from the outside to at least one of the two blank ends.

Abstract: A multi-piece hydroforming tool is provided having a tooling die and a hydraulic pressure source. The tooling die includes a plurality of tooling cavities. Each tooling cavity includes a injector manifold in fluid communication with the hydraulic pressure source. The injector manifolds supply pressurized hydraulic fluid to each of the plurality of tooling cavities independently. Thus, multiple pieces may be formed simultaneously and independently, thereby minimizing the need to discard all the hydroformed pieces if one piece become defective.

Abstract: A metal forming apparatus utilizes the combination of a wedge shaped die half and a complementary shaped cavity in a frame to shape metal blanks. The cavity includes a metal forming mechanism located adjacent a surface adapted to receive a blank to be shaped. The die half is moveable between an inoperative position outside the cavity and an operative position within the cavity. With the die half in the cavity, the metal forming mechanism can apply the necessary force to shape the metal blank in accordance with the die shape. Forming can be attained through the use of pressurized fluid applied against the blank, mechanical or hydraulic ram forces or the like. After shaping is finished, the die half is withdrawn from the cavity, the die half carrying with it the shaped metal part for part recovery and initiation of another forming cycle.

Abstract: The present invention relates to a method and apparatus for forming an elongated tubular metal member from a tubular metal blank. The method comprises: i) placing a tubular metal blank having a generally oval cross-section into a die cavity and orienting the tubular metal blank such that a relatively larger cross-sectional dimension of the generally oval cross-section extends generally in a direction of the relatively larger cross-sectional dimension of the die cavity and such that a relatively smaller cross-sectional dimension of the generally oval cross-section extends generally in a direction of the relatively smaller cross-sectional dimension of the die cavity; ii) engaging and sealing opposite ends of the tubular metal blank; and iii) injecting fluid under pressure into the tubular metal blank so as to expand the tubular metal blank into conformity with the surfaces defining the die cavity and thereby transform the tubular metal blank into the elongated tubular metal member.

Abstract: A blow molding method for use with tubular metal work pieces. The method involves placing a tubular metal component part into a molding tool having an internal molding cavity and at least one access passageway into which the component is inserted. The molding tool is then heated to a temperature between about 1000.degree. F. and 1200.degree. F. and a high pressure gas is injected into the tubular component. The high pressure gas causes the portion of the work component residing within the internal mold cavity of the molding tool to expand and assume the shape of the internal molding cavity. After a cooling period, the component is removed from the molding tool. The process is particularly well suited for forming the end support portions of side rails used with vehicle article carriers, but can be used to form a wide variety of complexly shaped forms from tubular metal workpieces.

Abstract: A method of manufacturing a metallic can body that is shaped distinctively in order to enhance its visual presentation to consumers includes, in one embodiment, steps of providing a can body blank that has a sidewall that is of a substantially constant diameter; providing a mold unit that has at least one mold wall that defines a mold cavity that is shaped generally like the can body blank, the mold wall having a pattern formed therein that corresponds to a desired final shape of the can body; positioning the can body blank within the mold cavity; and supplying a pressurized fluid into the mold cavity so that the can body blank is forced by pressure against the mold wall, causing the can body blank to assume the desired final shape of the can body.

Abstract: The invention relates to a hollow camshaft consisting of a metal or metal alloy or plastic which can be cold-formed and heat-treated and has a fiber flow parallel to the exterior contours of the camshaft, and to a method for producing it comprising the steps of:Placing a pipe outlet element and filling it with fluid;Sealing at least the pipe section to be widened;Applying an internal high pressure suitable for widening the pipe section to produce an intermediate product pre-form, wherein, while the internal high pressure is applied, the hollow pipe is compressed against a movable die in the direction of its long axis in such a way that accumulations of material occur at approximately those places where it is intended to create cams;Shaping the intermediate product pre-form into a shape corresponding to a final camshaft shape by means of the internal high pressure shaping method, so that cams are shaped at the desired locations;If necessary, finishing the cams by heat-treatment.