Ford Motor Company
Hydroforming of porthole extrusion with non-equiangular seams

Abstract:

A method of forming a part includes extruding a billet through a die, forming a round, closed geometry tube from the billet, and hydroforming the round, closed geometry tube. The extrusion die contains an orifice with a central mandrel, a plurality of bridges, and a corresponding plurality of portholes between the bridges. A spacing of the bridges around the mandrel is non-equiangular. As a result, the round, closed geometry tube has non-equiangular welds after emerging from the die.