Method of manufacturing a vehicle frame assembly

Abstract

A vehicular frame assembly is manufactured by initially providing a vehicular frame assembly that is formed from a plurality of structural members, each having an inherent torsional rigidity. Then, a desired inherent torsional rigidity can be determined for at least one of the plurality of structural members. Lastly, the at least one of the plurality of structural members can be deformed to achieve the desired inherent torsional rigidity. Alternatively, the vehicular frame assembly can be manufactured by initially providing a plurality of structural members, each having an inherent torsional rigidity. A desired inherent torsional rigidity can be determined for at least one of the plurality of structural members, and the at least one of the plurality of structural members is deformed to achieve the desired inherent torsional rigidity. Lastly, the plurality of structural members can be assembled to form the vehicular frame assembly.

1 . A method of manufacturing a vehicular frame assembly comprising the steps of: (a) providing a plurality of structural members, each having an inherent torsional rigidity; (b) determining a desired inherent torsional rigidity for at least one of the plurality of structural members; (c) deforming the at least one of the plurality of structural members to achieve the desired inherent torsional rigidity; and (d) assembling the plurality of structural members to form a vehicular frame assembly. 
   
   
       2 . The method defined in  claim 1  wherein said step (b) is performed by calculating the desired inherent torsional rigidity mathematically. 
   
   
       3 . The method defined in  claim 1  wherein said step (b) is performed by determining the desired inherent torsional rigidity empirically. 
   
   
       4 . The method defined in  claim 1  wherein said step (c) is performed by deforming the at least one of the plurality of structural members to have a generally C-shaped cross sectional configuration. 
   
   
       5 . The method defined in  claim 1  wherein said step (c) is performed by deforming the at least one of the plurality of structural members to have different diameter portions. 
   
   
       6 . The method defined in  claim 1  wherein said step (c) is performed by magnetic pulse forming. 
   
   
       7 . The method defined in  claim 1  wherein said step (c) is performed by forming portions of the at least one of the plurality of structural members from different materials. 
   
   
       8 . The method of  claim 1 , wherein the plurality of structural members comprises at least one cross member and a plurality of side members. 
   
   
       9 . The method of  claim 8 , wherein the step of deforming the at least one of the plurality of structural members comprises deforming the at least one cross member. 
   
   
       10 . A method of manufacturing a vehicular frame assembly, comprising:
 providing a plurality of structural members;   determining a desired handling characteristic for the plurality of structural members; and   deforming at least one of the plurality of structural members to achieve the desired handling characteristic.   
   
   
       11 . The method of  claim 10 , wherein the plurality of structural members each have an inherent torsional rigidity. 
   
   
       12 . The method of  claim 10 , wherein the plurality of structural members comprises at least one cross member attached to a plurality of side members. 
   
   
       13 . The method of  claim 10 , wherein the plurality of structural members is assembled to form at least a portion of a vehicle frame assembly. 
   
   
       14 . A method of manufacturing a vehicular frame assembly, comprising:
 determining a desired inherent torsional rigidity for a vehicle frame assembly;   providing a plurality of structural members, the plurality of structural members comprising cross members and side members, and wherein the cross members are formed of at least two different materials; and   assembling the structural members to form at least a portion of the vehicle frame assembly with the desired inherent torsional rigidity.   
   
   
       15 . The method defined in  claim 14 , further comprising deforming at least one of the structural members to achieve the desired inherent torsional rigidity. 
   
   
       16 . The method defined in  claim 14 , wherein the assembling of the structural members to form at least a portion of the vehicle frame is done by a welding process. 
   
   
       17 . The method defined in  claim 14 , wherein at least one of the cross members is formed with two different materials. 
   
   
       18 . The method defined in  claim 16 , wherein the welding process is a magnetic pulse welding process. 
   
   
       19 . The method defined in  claim 17 , wherein the at least one of the cross members formed with two different materials is formed with two different metallic materials. 
   
   
       20 . The method defined in  claim 17 , wherein the at least one of the cross members formed with two different materials is formed with a metallic material and a non-metallic material.