Method of hydroforming a front axle beam

Abstract

A method for manufacturing a non-driving, rigid axle beam for use in a vehicle frame and suspension system includes the initial step of providing a tubular blank. The tubular blank is disposed within a die having cooperating die sections that define a cavity having a shape that corresponds with the desired shape of the non-driving axle beam. Next, pressurized fluid is provided within the tubular blank so as to deform the tubular blank into conformance with the die cavity. A steering knuckle can be pivotably connected to each end of the non-driving axle beam by securing a hollow cylindrical support to each end of the non-driving axle beam and pivotably connecting a steering knuckle to each end of the hollow cylindrical supports. The non-driving axle beam can be formed having any desired cross sectional shape, including circular, triangular, I-shaped, and oval.

Dependencies are inferred from the claim text.