Abstract: A method for manufacturing a lower body component for a vehicle is provided including forming a one-piece floor pan at least partially defining a vehicle passenger compartment and substantially extending longitudinally at least the entire length thereof, and forming a one piece reinforcement structural member for reinforcing the pan. The method also includes simultaneously forming the pan and one-piece reinforcement structural member by stacking a pair of weldable sheet metal blanks sufficiently close together to define a comon interface, positioning the stacked blanks between moveable profile forming dies, heating the dies so that the blanks reach a superplastic forming temperature, and plastically deforming the stacked blanks into a lower body component having the profile of the dies. The method also includes friction stir welding of the stacked blanks at the common interface.

Abstract: An improved forming tool apparatus for forming an article having a negative draft angle that locks the formed article within the forming tool. First and second forming tools are closed relative one another to define a forming tool cavity in which the article is formed and opened for removal of the formed article from the forming tool cavity. The first forming tool has a removable cavity wall segment having an undercut cavity wall that provides a desired shape to the formed article but locks the formed article against removal from the forming tool cavity. A pivot linkage normally establishes the removable wall segment in a forming position in which the undercut wall is poised for forming of the article and selectively pivots the removable wall segment out of the forming position when the forming tools are opened so that the undercut wall is pivotally lifted and releases the formed article for removal from the cavity.

Abstract: A forming apparatus and method for minimizing wrinkling in the forming of a three-dimensional component from a two-dimensional blank. The forming apparatus includes vertically opposed sets of tools or binders. A first tool or binder apparatus has first and second sets of opposed sides having contoured binder surfaces. A second tool or binder apparatus is mounted in vertically opposed relation to the first binder apparatus, and includes first and second sets of opposed tool or binder segments that have contoured binder surfaces thereon that are complementary in shape to the respective binder surfaces of the first and second sets of opposed sides of the first binder apparatus. One of the first and second sets of opposed binder segments of the second binder apparatus have substantially similar contours and the other have different contours. One of the first and second sets of opposed binder segments of the second binder apparatus is elevated and movable with respect to the other.

Abstract: A method for forming sheet metal articles, such as automotive body panels, having complex curvatures. Opposing, complementary, pre-form and finish-form tools are used in a single press. A sheet of hot blow-formable sheet metal alloy, heated to a forming temperature, is placed between the tools. The pre-forming tool is lowered to a first stage closed position thereby trapping edges of the sheet between binder surfaces of the tools. The sheet is first stretched against the pre-form tool using pressurized gas to form a pre-form that undergoes most of the metal stretching required for the final part shape. Then the finish-form tool is pivotably advanced into a second stage closed position. The pre-form is displaced away from the pre-form tool and hot plastically formed against the opposing finish-form tool with pressurized gas to obtain the final sheet metal part shape. The finish-form tool is then pivotably retracted so as to avoid die lock or part interference conditions.

Abstract: A self-contained die cushion assembly for use in a stretch-forming process involving heated tooling. A lower plate is mounted below an upper plate that undergoes different thermal expansion than the lower plate. Guidance devices are mounted between the upper and lower plates and include a guide post, a bearing sleeve circumscribing the guide post, and a cylinder circumscribing the bearing sleeve. The guide post is mounted in fixed relation to the upper plate, and the cylinder is mounted in laterally translatable relation to the lower plate to accommodate lateral relative displacement between the upper and lower plates due to different thermal expansion thereof, thereby preventing binding of the guidance devices.

Abstract: A mechanical mechanism is disclosed for supplementing the action of a pressurized working gas in hot blow forming of a sheet material. Opposing complementary heated forming tools grip the sheet material and form a shaping surface on one side of the sheet and a gas pressure chamber on the other side. An internal complementary mechanical forming device is located inside the pressure chamber. The device is operated by an internal rotatable shaft supported through the chamber defining tool wall. The internal shaft is coupled outside the tool wall to an external shaft for external activation of the mechanical forming device. The external shaft and coupling are enclosed in a housing structure that provide a pressure seal, thrust support and thermal insulation for the external activation mechanism.

Abstract: A method is disclosed for forming sheet metal articles, such as automotive body panels, having significant curvatures in front-to-back and side-to-side directions. Opposing, complementary, preforming and final shape forming tools are used in a single press. A sheet of superplastically or quick plastically formable sheet metal alloy, heated to a forming temperature, is first stretched against the preform tool by the final shape tool to form a preform that has experienced most of the metal stretching required for the final part shape. The preform is removed from the preform tool and formed against the opposing, final shape tool with pressurized gas to obtain the final sheet metal part shape.

Abstract: A method is disclosed for forming sheet metal articles, such as automotive body panels, having significant curvatures in front-to-back and side-to-side directions. Opposing, complementary, preforming and final shape forming tools are used in a single press. A sheet of superplastically or quick plastically formable sheet metal alloy, heated to a forming temperature, is first stretched against the preform tool using pressurized gas to form a preform that has experienced most of the metal stretching required for the final part shape. The preform is removed from the preform tool and formed against the opposing tool with pressurized gas to obtain the final sheet metal part shape.

Abstract: Apparatus and method for hot blow-forming an article from a blank of sheet metal. Simultaneously, a surface of the blank of sheet metal is formed against a form tool body that partially defines a forming surface and against a form tool insert that also partially defines the forming surface and that is positioned within a recess of the form tool body such that a lateral gap is defined between the form tool insert and form tool body. Opposed projections are provided on upper surfaces of the form tool insert and the form tool body adjacent the gap. The projections create a raised portion on the sheet metal panel that corresponds to the gap. The raised portion is removed flush with respect to a visible surface of the article.

Abstract: A method is disclosed for forming sheet metal articles, such as automotive body panels, having significant curvatures in front-to-back and side-to-side directions. Opposing, complementary, preforming and final shape forming tools are used in a single press. A sheet of superplastically or quick plastically formable sheet metal alloy, heated to a forming temperature, is first stretched against the preform tool by the final shape tool to form a preform that has experienced most of the metal stretching required for the final part shape. The preform is removed from the preform tool and formed against the opposing, final shape tool with pressurized gas to obtain the final sheet metal part shape.

Abstract: A method is disclosed for forming sheet metal articles, such as automotive body panels, having significant curvatures in front-to-back and side-to-side directions. Opposing, complementary, preforming and final shape forming tools are used in a single press. A sheet of superplastically or quick plastically formable sheet metal alloy, heated to a forming temperature, is first stretched against the preform tool using pressurized gas to form a preform that has experienced most of the metal stretching required for the final part shape. The preform is removed from the preform tool and formed against the opposing tool with pressurized gas to obtain the final sheet metal part shape.

Abstract: A device is provided comprising a guide mechanism used to position and securely hold a sheet metal blank in a sheet metal forming press that is operated at high temperatures. A sheet metal blank is initially positioned in the forming press by resting the sheet metal blank on the highest portion of the convex surface of the lower tool member and counter balancing it with a blank loading device that includes a support hand to initially hold the blank. The guide apparatus comprises an engagement tool mounted to a beam that is slidably attached to guide supports. As the upper tool member drops, the engagement tool pinches and securely holds the sheet metal blank as the guide supports slide along the beam in sync with the downward movement of the upper tool member.

Abstract: A device is provided comprising a guide mechanism used to position and securely hold a sheet metal blank in a sheet metal forming press that is operated at high temperatures. A sheet metal blank is initially positioned in the forming press by resting the sheet metal blank on the highest portion of the convex surface of the lower tool member and counter balancing it with a blank loading device that includes a support hand to initially hold the blank. The guide apparatus comprises an engagement tool mounted to a beam that is slidably attached to guide supports. As the upper tool member drops, the engagement tool pinches and securely holds the sheet metal blank as the guide supports slide along the beam in sync with the downward movement of the upper tool member.