A vehicle space frame (10) for constructing a pick-up truck styled motor vehicle includes a body module (30) and a front module (22). The body module (20) includes a pair of laterally spaced, longitudinally extending main side rail structures (14) and a pair of rearward-most upright structures (26) each being connected to a respective main side rail structure and extending upwardly therefrom to form a pair of rearward-most pillars thereon. The body module further includes a pair of hydroformed upper longitudinal members (30, 32) each being defined by an outwardly deformed tubular metallic wall fixed in a predetermined irregular exterior surface configuration and each including a pillar-forming portion and a longitudinally extending portion. The front module (22) includes a pair of front lower side rail structures (18), a pair of front upper side rail structures (42) and front connecting structure (44). The front connecting structure connects the front lower side rail structures to one another in laterally spaced relation and to connect the front upper side rail structures to one another in laterally spaced relation. The front module (22) is fixed to the body module (20) by rigidly interconnecting each front lower side rail structure with a respective main side rail structure (14) and each front upper side rail structure to pillar-forming portion of a respective hydroformed upper longitudinal member at a position spaced upwardly from the associated main side rail structure (14).

Modular space frame

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.

Hydroformed control arm

A frame assembly for a motor vehicle comprises a forward module (12) and a rearward module (14). The forward module (12) comprises a pair of forward side rail portions (16, 18), which are interconnected by a cross portion (20). The forward side rail portions (16, 18) are angularly disposed with respect to one another such that they have an increasing distance therebetween as they extend rearwardly. Rearward ends (28, 30) of the forward side rail portions (16, 18) are connected to associated forward ends (32, 34) of the rearward side rail portions (22, 24). At least one of the forward and rearward side rail portions has a notch (30) formed therein permitting an end portion thereof to be bent laterally to permit interface with the associated side rail portion connected thereto. The end portion is then bent back and is welded to the associated side rail portion connected thereto.

Method of joining closed section members between frame modules

A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to density the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

Controlled pressure casting

A hydroforming assembly has a plurality of die structures that are mounted on a press for reciprocating movement between open and closed conditions. The die structures have cooperating die surfaces defining a die cavity when in the closed condition and receive a metallic tube blank when in the open conditions. A hydroforming fluid supply system has tube-end engaging structures that are movable to selectively and sealingly engage opposite ends of the tube blank. The hydroforming fluid supply system provides pressurized fluid into an interior of the tube blank in order to expand the tube blank outwardly into conformity with the die cavity. A punch extends within a passage of at least one of the die structures. The punch is movable between retracted and extended positions. A punch driving assembly drives the punch between the retracted and extended positions to punch a hole into the expanded tube blank. A flushing system communicates with the die cavity providing a flushing fluid flow through the interior of the expanded tube blank.

Hydroforming flush system

A die assembly having die structures that are cooperable to define a die cavity into which a metallic tubular blank can be disposed. A first die structure is moveable to seal the die cavity, and after the die cavity is sealed, the first and second die structures are moveable to reduce the cross-sectional area of the die cavity and thereby deform the metallic tubular blank within the die cavity.

Cross James M

Papers

Hydroforming die assembly for pinch-free tube forming

Hydroforming die assembly and method for pinch-free tube forming

Verfahren und vorrichtung zum hydroformen von rohren