Patent EA-002942-B1 (EA)
Title: Self-extruded bushing assembly and method of making the same
Inventor: BEAN WILLIAM C
IPC: B21D53/88
Filed: 1999-02-12
Abstract: 1. A method for mounting a bushing into a metal member, said method comprising: providing a metal member having first and second opposing surfaces with a thickness between said surfaces which is relatively small in comparison to the surface area of said surfaces, forming a bushing receiving opening in said metal member, said opening defined by an annular edge portion surrounding said opening; positioning a bushing adjacent to said first opposing surface and forcing said bushing through said opening in a bushing driving direction such that said bushing engages said annular edge portion and deforms said annular edge portion in said bushing driving direction to form an annular flange portion on said metal member which projects in said driving direction and engages an exterior surface of said bushing in an interference fit relation so as to securely retain said bushing within said opening. 2. A method according to Claim 1, wherein said bushing is generally cylindrical and said bushing receiving opening is generally circular. 3. A method according to Claim 2, further comprising: before forcing said bushing through said opening, positioning a supporting die to support a portion of the second opposing surface adjacent said opening while said bushing is being forced through said opening so that only said annular edge portion of said metal member is substantially deformed by said bushing. 4. A method according to Claim 3, wherein said supporting die has a bushing receiving space positioned and configured to receive said bushing as said bushing is being forced through said bushing receiving opening. 5. A method according to Claim 4, wherein said supporting die has an angled edge portion surrounding said bushing receiving space, said angled edge portion being positioned adjacent to said annular edge portion while said supporting die supports said bushing mounting portion such that said annular edge portion is deformed against said angled edge portion and said angled edge portion limits the deformation of said annular edge portion. 6. A method according to Claim 2, further comprising: before forcing said bushing through said bushing receiving opening, aligning said bushing with said bushing receiving opening; and wherein said bushing is thereafter forced through said bushing receiving opening by engaging a driving tool with said bushing and moving said tool in said bushing driving direction. 7. A method according to Claim 6, further comprising: after forcing said bushing through said bushing receiving opening, disengaging said driving tool from said bushing such that said deformed annular flange portion resiliently moves inwardly against said bushing to enhance the aforesaid interference fit relation. 8. A method according to Claim 1, wherein said metal member is a sheet of steel material. 9. A method according to Claim 1, wherein said metal member is a tubular member. 10. A method according to Claim 9, wherein said tubular member is hydroformed into a desired configuration. 11. A method according to Claim 1, wherein said bushing comprises an outer metal can member with an annular side wall portion and a bottom wall portion integrally formed with said annular side wall portion, said bushing further comprising mounting structure extending upwardly from said bottom wall portion beyond an upper edge of said side wall portion, and shock absorbing material disposed inside said can member in surrounding relation with respect to said mounting structure. 12. A method according to Claim 11, wherein said mounting structure is a tubular mounting sleeve. 13. A method according to Claim 11, wherein said shock absorbing material is rubber. 14. A metal member and bushing assembly comprising: a metal member having first and second opposing surfaces with a thickness between said first and second opposing surfaces which is relatively small in comparison to the surface area of said first and second surfaces, said metal member having a bushing receiving opening formed therethrough and an annular flange portion surrounding said opening and projecting from said metal member in a bushing driving direction; and a bushing securely mounted inside said bushing receiving opening with said annular flange portion engaging said bushing in an interference fit relation as a result of said bushing being positioned adjacent said first opposing surface and forced through said bushing receiving opening in said bushing driving direction such that said bushing engages an annular edge portion surrounding said opening and deforms said annular edge portion in said driving direction to form said annular flange portion. 15. A sheet metal member and bushing assembly according to Claim 14, wherein said bushing is generally cylindrical and wherein said bushing receiving opening is generally circular. 16. A sheet metal member and bushing assembly according to Claim 15, wherein said bushing comprises an outer metal can member with an annular side wall portion and a bottom wall portion integrally formed with said side wall portion; said bushing further comprising a mounting member extending upwardly from said bottom wall beyond an upper edge of said annular side wall portion, and shock absorbing material disposed inside said can member in surrounding relation with respect to said mounting member. 17. A sheet metal member and bushing assembly according to Claim 16, wherein said mounting member is a tubular mounting sleeve. 18. A sheet metal member and bushing assembly according to Claim 14, wherein said metal member is a sheet of steel material. 19. A sheet metal member and bushing assembly according to Claim 14, wherein said metal member is a tubular member. 20. A sheet metal member and bushing assembly according to Claim 19, wherein said tubular metal member is hydroformed into a desired configuration. 21. A method for making a vehicle frame member with a shock absorbing mounting structure to be mounted to another structural component of a motor vehicle, said method comprising: providing a tubular member surrounding a hollow interior, said tubular member having a lateral opening formed therethrough and an annular edge portion surrounding said opening, said tubular member having a first opposing surface facing outwardly away from said hollow interior and a second opposing surface facing inwardly towards said hollow interior with a thickness between said opposing surfaces which is relatively small in comparison to the surface areas of said opposing surfaces; providing a shock absorbing mounting structure having a mounting portion constructed and arranged to be secured to the structural component of the motor vehicle and a yieldable shock absorbing portion associated with said mounting portion; positioning said shock absorbing mounting structure adjacent said first opposing surface and forcing said mounting structure inwardly with respect to said tubular member through said opening such that said mounting structure engages said annular edge portion and deforms said annular edge portion inwardly into the hollow interior of said tubular member to form an annular flange portion that engages an exterior surface of said mounting structure in an interference fit relation so as to securely retain said mounting structure within said opening, thereby enabling said tubular member to be resiliently mounted to the aforesaid structural component; and supporting a portion of said second opposing surface adjacent said opening while said mounting structure is being forced through said opening such that only said annular edge portion is substantially deformed by said mounting structure. 22. A method according to Claim 21, further comprising: before forcing said mounting structure through said opening, positioning a supporting die adjacent said portion of said second opposing surface adjacent said opening such that said supporting die supports said tubular wall while said mounting structure is being forced through said opening so that only said annular edge portion is substantially deformed by said mounting structure. 23. A method according to Claim 22, wherein said supporting die has a mounting structure receiving space positioned and configured to receive said mounting structure as said mounting structure is being forced through said opening. 24. A method according to Claim 23, wherein said supporting die has an angled edge portion surrounding said bushing receiving space, said angled edge portion being positioned adjacent to said annular edge portion while said supporting dies supports said mounting portion such that said annular edge portion is deformed against said angled edge portion and said angled edge portion limits the deformation of said annular edge portion. 25. A method according to Claim 21, further comprising: before forcing said mounting structure through said opening, aligning said mounting structure with said opening; and wherein said mounting structure is thereafter forced through said opening by engaging a driving tool with said mounting structure and moving said tool inwardly with respect to said tubular member. 26. A method according to Claim 25, further comprising: after forcing said mounting structure through said opening, disengaging said driving tool from said mounting structure such that said deformed annular flange portion resiliently moves inwardly against said mounting structure to enhance the aforesaid interference fit relation. 27. A method according to Claim 21, wherein said shock absorbing mounting structure is a generally cylindrical bushing. 28. A method according to Claim 27, wherein said mounting structure comprises an outer metal can with an annular side wall portion and a bottom wall portion integrally formed with said side wall portion, said mounting portion of said mounting structure being a mounting member projecting generally upwardly from said bottom wall portion beyond an upper edge of said side wall portion, said mounting member being construc