Engine cradle for vehicle body and frame assembly and method of

Abstract

An engine cradle is formed from tubular stock material using mechanical bending and hydroforming techniques. To facilitate connections with the body and frame assembly of the vehicle, hollow end portions of the engine cradle are subjected to an end forming operation. The result of the end forming operation is that the hollow end region of the engine cradle is deformed to have a generally U-shaped cross section having an aperture formed therethrough. The central portion of the U-shaped end region is flat so as to facilitate the connection of the engine cradle to the body and frame assembly of the vehicle. The central portion also has an effective wall thickness which is equal to the sum of the wall thicknesses of the upper and lower walls of the original hollow region. Similarly, the side portions of the U-shaped end region are also flat and have double wall thicknesses. Consequently, the U-shaped end region is quite strong and rigid, allowing it to be connected directly to the body and frame assembly of the vehicle without ancillary support devices, such as rigid spacers. The U-shaped end region also provides desirable lateral and torsional rigidity to the joint between it and the body and frame assembly.