Magna International Inc.

John Dicesare

Mark W Barber

Gianfranco Gabbianelli

Frank A Horton

Richard Ashley

William R Perry

Ashwani K Aggarwal

Robert M Kaminski

William Perry

Ashwani Aggarwal

A method for manufacturing a hydroforming member includes the step of providing a blank (). The blank () is defined by blank wall (). The blank () is placed in a die assembly () having a die cavity () defined by a die surface (). The blank () is expanded so that the blank wall () is forced against the die surface () to form the hydroformed member. A portion of the blank wall conforms against a wall-thinning element () positioned along the die surface () to form a removable wall section () in a portion of the blank wall (). The removable wall section () is then removed from the blank wall () to form an opening in the hydroformed member.

Method of forming hydroformed member with opening

A method for forming a hollow part () that allows the use of hydroforming in cases where the part interconnects between sections having extreme variations in cross-section. A complete hollow part () is formed by joining a hydroformed hollow section with hollow sections. A method for securing a fastener sleeve () insert in a pre-fabricated hollow part () is also provided. In this method, the hollow part () is deformed slightly to form flanges () that secure the insert () in the part. Once the insert () is secure in the hollow part, fasteners can be applied to the part without collapsing it.

Method of securing a sleeve in a tubular member

An assembly of supporting members includes a first member overlapping a second member and positioned within a hollow interior of the second member. The hollow interior of the second member has a flange on which the first member rests. A leading edge of the first member may have a protrusion extending away from the first member towards the flange of the second member to protect the flange and the connection between the first and second members. The first and second members may be hydroformed with the protrusion being an integral element of the first member.

Frame assembly for a motor vehicle

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London, Canada

John Dicesare