Gm Global Technolgoy Operations, Inc.

Chi-Mou Ni

Charles J Bruggemann

Joseph M Lendway, Iv

Chih-chang Chen

Daniel C Hutchinson

Steven K Mackenzie

Tehui Peng

Thomas B Bartholomew

Michael J Pevovar

Michael G Poss

Matthew J Noone

Edward J Strzelecki

Alexander Michael Turley

Wallace T Hall

Ferdous M Ghazi

John A Roby

James P Chatterley

William Henry Todd, Jr

Tasnim Hassan

Paul B Cobble

Eric B Washington

Peter A Tropper

A variable thickness member for a vehicle includes a first portion having a first thickness and a second portion extending from the first portion having a second thickness. The first thickness is different from the second thickness and the first thickness and the second thickness are integral, unitary, and one piece.

Method of making a variable thickness member for a vehicle

A hydroformed dovetail joint and method of joining tubular members includes a first hydroformed tubular member having a depression therein and a second hydroformed tubular member having an end. The end of the second hydroformed tubular member is disposed over the depression of the first hydroformed tubular member to join the first hydroformed tubular member and the second hydroformed tubular member together to form a dovetail joint between the first hydroformed tubular member and the second hydroformed tubular member.

Method of joining hydroformed tubular members

A hydroformed and roll-formed cross sill assembly for a vehicle and method of making same includes a pair of hydroformed tubular side members. The hydroformed and roll-formed cross sill assembly also includes a roll-formed beam member disposed between the tubular side members and at least one weld to secure the beam member to each of the tubular side members.

Hydroformed and roll-formed cross sill assembly for vehicles and method of making same

A grille guard assembly for a vehicle and method of making same includes a hydroformed tubular upper member and a hydroformed tubular lower member. The grille guard assembly also includes at least one inner member interconnecting the upper member and the lower member. The grille guard assembly further includes at least one bracket connected to the lower member for attachment to vehicle structure.

Vehicle grille guard assembly

A method of progressive hydro-forming of a tubular member includes the steps of positioning a tubular member between open die halves mating with one another to define a first tubular cavity portion in a first stage. The method also includes the steps of progressively closing the die halves and applying hydraulic pressure to expand and conform the tubular member to the first tubular cavity portion in the first stage. The method includes the steps of positioning the expanded tubular member in a second tubular cavity portion in a second stage and progressively closing the die halves to progressively deform the expanded tubular member within the second tubular cavity portion. The method includes the steps of applying hydraulic pressure to expand and conform the expanded tubular member to the second tubular cavity portion in the second stage.

Method of progressive hydro-forming of tubular members

A method of making a pre-formed tubular member includes the steps of providing a tubular member extending longitudinally and providing a bending assembly having a mandrel with at least one ball and a bending die. The method also includes the steps of positioning the at least one ball inside of the tubular member. The method further includes the steps of bending the tubular member about the bend die to form a bent pre-formed tubular member having at least one curved portion having a recess therein.

Method of making pre-formed tubular members

A method of single sided spot welding includes the steps of providing a metal tube having a convex surface portion and providing a metal sheet for welding to the metal tube. The method also includes the steps of contacting the metal sheet with the convex surface portion of the metal tube and contacting the metal sheet with a welding electrode. The method further includes the steps of supplying power to the welding electrode for melting metal and solidifying the molten metal to form a weld nugget between the metal sheet and the metal tube.

Method for single sided spot welding

The present invention is for a method of lap joining two tubular members and then hydroforming the tubular assembly. An insert end of the first tubular member is inserted into a receiver end of the second tubular member to form a lap joint. A filler metal ring is placed about the outer periphery of the insert end so that it is adjacent the opening of the receiver end of the second tubular member. Heat is applied to braze or solder the lap joint, forming a tubular assembly. The tubular assembly is then hydroformed during which time a supplementary mechanical lock may be formed in the lap joint.

Joining and forming of tubular members

A hydroformed tubular structure includes at least two hydroformed members connected at a joint. At least one of said members includes a flattened portion having opposite sides in engagement. One of the sides engages and is secured to a mating portion of another of the members and a hydroformed conjugate portion is formed in the one side adjacent the flattened portion and is secured in a recess of the other member. A hydroformed structural portion extends from the conjugate portion in a direction away from the flattened portion. A method of making the structure includes the steps of placing a tubular member in a hydroforming die, filling the tubular member with hydroforming liquid, flattening at least one portion of the tubular member intermediate its ends by forcing opposite sides of the member into engagement upon closing of the die, the liquid in the member acting to prevent collapse of other portions of the tubular member than the flattened portions, hydroforming the member into a predetermined configuration including expanded conjugate portions adjacent the flattened portions, trimming the flattened portions of the member to form a plurality of separate hydroformed parts each having at least one flattened end portion with an adjacent expanded conjugate portion, and securing the flattened portion of a first one of the parts to a second part having a recess receiving the conjugate portion of the first part to form a secure joint connecting the first and second parts.

Hydroformed tubular structures and methods of making

Apparatus and method for hydroforming multiple components simultaneously with a smaller capacity press than would be possible using conventional hydroforming methods and apparatus. Die pairs are positioned with multiple die cavities in series so that the separating force transmitted to a press holding the dies equals the force developed in a single die cavity, even though multiple components are being formed in the die cavities.

Method and apparatus for hydroforming multiple components with reduced press loading

A vehicle frame has side rails which support the suspension system and body of the vehicle. The side rails have a rectangular cross-section with the end sections thereof having predetermined wall thicknesses and rectangular size, and a center section having a thinner wall thickness and a larger height dimension of the rectangular cross-section. A transition section connects respective end sections with the center section. The transition section has rectangular cross-sections and wall thickness at the respective junctures which matches the adjoining section. The frame side rail is manufactured by prebending a cylindrical tube of constant wall thickness into a shape consistent with the desired final shape; then hydroforming an intermediate work piece in a first die to provide wall thickness and perimeter characteristics commensurate with the final product; and then further hydroforming the intermediate work piece in a second die to provide the finished product or to provide two components which are joined to form the final frame side rail. When two intermediate work pieces are processed, each is formed with an end section and a part of the center section.

Hydroformed side rail for a vehicle frame and method of manufacture

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.

Method for hydroforming a hollow sheet metal body part

A vehicle space frame is built up piece by piece into an initial or rough frame, consisting of standard, cylindrical metal tubes welded to matching cylindrical plugs of hollow, nodal joints. All weld seams are circular and, therefore, easily and quickly formed, and the initial frame need be formed only with the accuracy that plugging the ends of the tubes into the joints will achieve. The entire interior of the initial frame is then clamped between a large pair of dies with mating cavities, and hydroformed to provide a final frame with the desired non cylindrical cross section and accurate, final shape and form.

Method for hydroforming a vehicle space frame

A method for hydroforming a tubular structural member of generally polygonal, flat walled cross section in which the various walls in the final part do not have the same thickness. A cylindrical tubular blank is extruded in which the outer surface is round, but in which the inner surface is asymmetrical, providing several contiguous angular sectors or portions of varying width and thickness. Each individual angular portion is tailored as to thickness and width to correspond to a respective wall in the final part. The blank is oriented between in a die cavity so as to align each angular portion with a respective wall of the finished part, and hydroformed in conventional fashion.

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Washington, MI, United States of America

Chi-Mou Ni