The present invention relates to a motor vehicle crash box with a working direction in vehicle's longitudinal axis manufactured out of a tube which is expanded into different zones, wherein the zones are different in strength and diameter by using steel after forming a homogenous austenitic microstructure with a strain hardening effect. The present invention further relates to the manufacturing method of such a component.

In extrusion processing in which diameter reduction is performed by pressing a raw pipe having a core bar inserted therein into a die having a small inner diameter portion on its tip end side, a differential thickness pipe having a thick-walled portion at its tip end can be molded using a core bar having a small cross-section portion formed at its tip end. It is also possible to mold a differential thickness pipe having a thick-walled part at an intermediate axial position by using a raw pipe having a thin-walled portion at its tip end. For example, such a raw pipe can be molded by extrusion processing using a core bar having no small cross section portion at its tip end, prior to the above-described formation of the thick-walled portion. When higher dimensional accuracy is required, a so-called “counter punch” may be used in the formation of the thick-walled portion.

A method for manufacturing a hollow vehicle frame part includes: removing material from a first side of a first billet, creating a first inner shape of a target vehicle frame; removing material from a first side of a second billet to create a second inner shape of a target vehicle frame; bonding the billets together at the faying surfaces on first sides of the billets so the inner shapes face each other; and removing material by machining from the second sides of the first and second billets to create target outer shape of the vehicle frame part. The method further includes forming additional faying surfaces adjacent and at an angle to the faying surfaces on the first sides of the first and second billets, which faying surfaces together form a rabbet-type joint where the first billet and second billet are bonded. A corresponding us vehicle frame is also disclosed.

A method for manufacturing a hollow vehicle frame part includes: removing material from a first side of a first billet, creating a first inner shape of a target vehicle frame; removing material from a first side of a second billet to create a second inner shape of a target vehicle frame; bonding the billets together at the faying surfaces on first sides of the billets so the inner shapes face each other; and removing material by machining from the second sides of the first and second billets to create target outer shape of the vehicle frame part. The method further includes forming additional faying surfaces adjacent and at an angle to the faying surfaces on the first sides of the first and second billets, which faying surfaces together form a rabbet-type joint where the first billet and second billet are bonded. A corresponding us vehicle frame is also disclosed.

A method is used to manufacture an article using a machine having a fixed base and a press structure movable toward the fixed base. The machine also includes a die assembly and a container both coupled to the fixed base. The machine further includes a mandrel assembly comprising a rotatable platform coupled to the press structure and having a first platform mandrel aligned with the die assembly and a second platform mandrel aligned with the container. The method includes the steps of placing a first starting component into the die assembly, pressing the first starting component to form the article, moving the second platform mandrel into the container simultaneously with the step of pressing the first starting component, and rotating the rotatable platform to align the second platform mandrel with the die assembly and to align the first platform mandrel with the container.

A method of manufacturing a filter pipe for vehicles which has an expanded tube portion with a different diameter at one side and is provided with a plurality of through holes formed along a circumferential direction includes: forming the plurality of through holes in a mother member; forming furrows at one end portion of the mother member; forming a planar member having the plurality of through holes and the furrows by a shearing process of the mother member; bending the planar member in a tubular shape and spreading the furrows to form an area where the furrows are formed in an expanded tube shape; and adhering both facing end portions of the planar member so as to form a body having the expanded tube portion at one side thereof.

A method of manufacturing a filter pipe for vehicles which has an expanded tube portion with a different diameter at one side and is provided with a plurality of through holes formed along a circumferential direction includes: forming the plurality of through holes in a mother member; forming furrows at one end portion of the mother member; forming a planar member having the plurality of through holes and the furrows by a shearing process of the mother member; bending the planar member in a tubular shape and spreading the furrows to form an area where the furrows are formed in an expanded tube shape; and adhering both facing end portions of the planar member so as to form a body having the expanded tube portion at one side thereof.

A method of production of a shaped article able to suppress occurrence of shaping defects, that is, a method of production of a shaped article including a first step of press-forming a metal plate (1a) into a U-shape to obtain a U-shaped article (1b) having a bottom part (2) straight extending in a longitudinal direction and a second step of press-forming the U-shaped article (1b) to bend it in the longitudinal direction so that the bottom part (2) of the part projects to the inside and obtain a U-cross-section bent article (1c).

A method of production of a shaped article able to suppress occurrence of shaping defects, that is, a method of production of a shaped article including a first step of press-forming a metal plate (1a) into a U-shape to obtain a U-shaped article (1b) having a bottom part (2) straight extending in a longitudinal direction and a second step of press-forming the U-shaped article (1b) to bend it in the longitudinal direction so that the bottom part (2) of the part projects to the inside and obtain a U-cross-section bent article (1c).

Metallic tubular products having improved collapse resistance are disclosed. The metallic tubular products are produced by compressive forming processes. The method comprises identifying the types of stress that can be applied in order to change the residual stress profile of metallic tubular products, such as those that have completed a straightening process, and results in a residual stress profile that improves collapse resistance. The metallic tubular products are subjected to radial compression processing to control the residual stress profile and to enhance collapse resistance. The radial compression process may be used after the tubular product has been subjected to a straightening process.