Patent ID: 8171769

Claim:
A method of forming a flanged tubular member, comprising the steps of: positioning a tubular blank between open, mating die halves, the tubular blank having an interior surface and an outer surface with a wall therebetween, the die halves defining: a die tubular cavity portion; a die hem cavity portion; and a die flange cavity portion; then applying at least nominal internal hydraulic pressure to the blank interior; closing the die halves, thereby substantially simultaneously: deforming the blank within the die tubular cavity portion; defining a flange from a first portion of the blank in the die flange cavity portion; and defining at least an intermediate hem from a second portion of the blank in the die hem cavity portion; and increasing the hydraulic pressure to expand and conform the outer surface of the blank to the die tubular cavity portion and the die hem cavity portion, thereby converting the tubular blank to a hydroformed member having the flange and a hem with a cavity therein.