Method for forming a complex-shaped tubular structure

• Main Authors: GOEBEL MARK, BENTON PAUL A, BRUGGEMANN CHARLES J, NGO TUAN A, LENDWAY, IV JOSEPH M, ROBINSON CARL W, MELLAS SPYROS P, PARLOW PETER M
• Format: Patent
• Language: English
• Published: 03.02.2009
• Subjects: COMBINED OPERATIONS; MACHINE TOOLS; MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVINGMATERIAL; METAL-WORKING NOT OTHERWISE PROVIDED FOR; OTHER WORKING OF METAL; PERFORMING OPERATIONS; PUNCHING METAL; TRANSPORTING; UNIVERSAL MACHINE TOOLS; WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS ORPROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL

A method is provided for forming a complexly-shaped tubular structure such as a tapered pillar or other structure for a vehicle body. A sheet metal blank having a longitudinal axis is rolled about the longitudinal axis to form a tubular shape and the side edges of the blank are then welded together to form a tube. The tube is then enclosed in a hydroforming die and pressurized to conform the tube to the shape of the die and thereby form the desired complex shape. The sheet metal blank may be formed by the end-to-end welding together of a plurality of separate sheet metal blanks that differ from one another in characteristic including material thickness, material alloy composition, and/or coating. One or more of the blanks can have side edges that are non-parallel so that the tube will taper in diameter along its length.