Process of hydroforming tubular suspension and frame components for vehicles

A process of manufacturing a tubular suspension component for a vehicle, said suspension component having an integral tubular configuration with an outer end and an inner end, said process comprising the steps of:

• selecting a tubular blank having a predetermined length, width and material wall thickness;
• sealing the ends of said tubular blank and introducing a pressurizing fluid to the interior of said tubular blank, said fluid pressurized to a predetermined level to support said wall of said blank without deforming said wall;
• bending said tubular blank to a predetermined curvature while maintaining fluid pressurization with said blank;
• positioning said bent tube in a cavity having a wall configuration conforming to the configuration of said suspension component and including at least one secondary cavity for integrally forming a subcomponent of said suspension component;
• increasing the internal fluid pressure within said bent tube to expand said tube into engagement with the wall of said die cavity including expanding the wall of said bent tube into said at least one secondary cavity to form said at least one integral subcomponent of said suspension component;
• and
• depressurizing said tubular component and releasing said integral suspension component from said die cavity.