Hydroform Tubes for Automotive Body Structure Applications

A new tube forming technology for automotive body structural components has been developed which offers the advantages of tubular parts combined with the part shape flexibility of stamped box section assemblies. The final tube form can have any geometry and cross section shape and can change continuously throughout the length of the part. Parts are typically 1000 to 4000 mm long. During the manufacturing process, round tubes are formed to their final shape in a closed cavity die with high internal pressure, and at the same time all required holes, are pierced in the tube. These parts offer advantages over stamped assemblies, such as reduced tooling, improve dimensional accuracy, reduced weight, and increased strength and stiffness.