In the proposed hydro ironing method, through an innovative arrangement of loads and using a novel configuration for the die components, the thickness reduction in one stage of ironing is almost equal to twice the common approaches.

A method of manufacturing a hollow structural frame rail includes rotating a tube relative to a tool to reduce an outside diameter of the tube at predetermined positions along the length of the tube. An elastomeric insert is positioned within the tube. The tube is bent at a location containing the insert. The bent tube is hydroformed to define a finished shape of the frame rail.

A method of manufacturing a hollow structural frame rail includes rotating a tube relative to a tool to reduce an outside diameter of the tube at predetermined positions along the length of the tube. An elastomeric insert is positioned within the tube. The tube is bent at a location containing the insert. The bent tube is hydroformed to define a finished shape of the frame rail.

An electrically assisted forming process and device for a high-strength metal alloy thin-walled pipe includes a die sleeve, wiring terminals, a pulse power supply, a die seat, sealing baffle plates, a drawing die, and a cooling water circulation chamber. A process for forming a high-strength metal alloy thin-walled pipe includes first, graphite or fusible metal, i.e., an aluminum rod, is introduced into a high-strength metal alloy pipe to be drawn to fill the whole pipe; and then, pulse current is introduced into a plastic deformation area of the thin-walled pipe. A cooling device can be provided to achieve a good cooling effect. The thin-walled pipe with corresponding length is cut according to a production requirement after processing is completed, and annealing treatment is performed in a vacuum heat treatment furnace.

An electrically assisted forming process and device for a high-strength metal alloy thin-walled pipe includes a die sleeve, wiring terminals, a pulse power supply, a die seat, sealing baffle plates, a drawing die, and a cooling water circulation chamber. A process for forming a high-strength metal alloy thin-walled pipe includes first, graphite or fusible metal, i.e., an aluminum rod, is introduced into a high-strength metal alloy pipe to be drawn to fill the whole pipe; and then, pulse current is introduced into a plastic deformation area of the thin-walled pipe. A cooling device can be provided to achieve a good cooling effect. The thin-walled pipe with corresponding length is cut according to a production requirement after processing is completed, and annealing treatment is performed in a vacuum heat treatment furnace.