Abstract: A steel has a predetermined chemical composition with a balance being Fe and incidental impurities, wherein a sum of Cu content and Ni content is 0.15 mass % or more, and a crystal grain size after forming into a stabilizer shape and quenching is in a range of 7.5 to 10.5 in prior austenite crystal grain size number. Thus, a highly durable stabilizer steel that has a tensile strength of 1200 MPa or more and excellent normal-temperature and low-temperature toughness and is used in an environmentally friendly manufacturing process at lower cost can be realized.

Abstract: A low carbon resulfurized free cutting steel consisting of 0.04 to 0.15% of C, more than 0.10% and 0.70% or less of Si, 0.85 to 1.50% of Mn, 0.040 to 0.120% of P, 0.250% or more and less than 0.400% of S, less than 0.005% of Al, more than 0.0020% and 0.0120% or less of O, and more than 0.0070% and 0.0150% or less of N, all by mass percentage, and the balance of Fe and inevitable impurities, and satisfying a formula (1) and a formula (2), as follows: 0.15%?Si %+2×P %?(5×Al %+10×O %+3×N %)?0.75%??(1), and ([Mn %]5)/15<S %<([Mn %]5)/2??(2).

Abstract: According to one embodiment, a high-strength stabilizer steel for vehicles having excellent corrosion resistance and low-temperature toughness, containing 0.07 to 0.20% C, more than 0.6% and 1.5% or less Si, 1 to 3% Mn, 0.1 to 1.0% Cr, 0.005 to 0.080% sAl, 0.005 to 0.060% Ti, 0.005 to 0.060% Nb, 0.070% or less Ti+Nb, 150 ppm or less N, 0.035% or less P, 0.035% or less S, 0.01 to 1.00% Cu, 0.01 to 1.00% Ni, the remainder being Fe, and unavoidable impurities, wherein a structure before molding a stabilizer is any one of a bainite, a martensite, and a mixed structure of bainite/martensite and an original austenitic crystal grain size number after a heat treatment of the stabilizer is Gh 9 or more.

Abstract: A low carbon free cutting steel can be obtained by allowing the steel to contain 0.02 to 0.15 mass % of C, 0.05 to 1.8 mass % of Mn, 0.20 to 0.49 mass % of S, more than 0.01 mass % and not more than 0.03 mass % of O, 0.3 to 2.3% of Cr, and the balance consisting of Fe and inevitable impurities, the Cr/S ratio falling within a range of between 2 and 6.

Abstract: An apparatus includes a roll former for forming a continuous beam from sheet material, and a downstream former positioned in-line and downstream of the roll former. The downstream former includes a die-supporting sled temporarily movable with the beam, and includes a bottom die, side dies reciprocatingly movable inwardly to temporarily support sides of the beam, and a top die reciprocatingly movable to reform flanges on the beam against the side dies to reform portions of a section of the continuous beam. A related method is also shown.

Abstract: A bumper system includes a rollformed tubular beam with bracket mounts welded to a rear surface for mounting to vehicle frame rails. The illustrated beam has a continuous tubular cross section for its entire length, and includes a center section, corner-forming end sections, and mounting sections connecting ends of the center section to the end sections. The center, end and mounting sections can be linear or similarly curved or differently curved. The center, end and mounting sections can be similarly or differently locally annealed as part of being tuned to specific impact loading criteria, including annealing all or part of cross-sectional areas. The annealing can be done in-line with a rollforming process, such as to assist with forming tight radii in the beam for meeting packaging/space-related requirements, or can be part of a secondary process for advantageously affecting impact strengths in selected localized areas.

Abstract: An energy management system comprising a longitudinally extending beam including a first beam portion and a second beam portion. A first one of the first beam portion and the second beam portion has a first face, a first side wall and a second side wall. A second one of the first beam portion and the second beam portion has a second face. The first side wall has a first U-shaped section spaced from the first face and the second side wall has a second U-shaped section spaced from the first face. The first side wall rolls to enlarge the first U-shaped section and the second side wall rolls to enlarge the second U-shaped section during an impact force directed against the first face of the first beam portion or the second face of the second beam portion.

Abstract: An energy-absorbing system includes a tube made of a continuous polymeric material. The tube has first and second tube sections connected by an intermediate tube section. By this arrangement, upon the bumper system receiving a longitudinal impact, the first and second tube sections telescopingly collapse with a predictable and consistent rolling collapse.

Abstract: A computer controlled roll-forming apparatus is adapted to provide a repeating pattern of different longitudinal shapes to a continuous beam “on the fly” during the roll-forming process. A sweep station on the apparatus includes a primary bending roller tangentially engaging the continuous beam along the line level and an armature for biasing the continuous beam against the primary bending roller for a distance partially around a downstream side of the primary bending roller to form a sweep. Further, actuators adjustably move the armature at least partially around the downstream side of the primary bending roller between at least first and second positions for imparting multiple different longitudinal shapes into the continuous beam. In one form, the apparatus also includes a coordinated cut-off, so that when separated into bumper beam segments, the ends of the individual beam segments have a greater sweep than their center sections.

Abstract: A towing apparatus mounted to a frame of a vehicle includes a receiver and an energy management device. The receiver is operably connected to the energy management device and the energy management device is operably connected to the vehicle frame. When the receiver is moved in a first tow direction, the energy management device is isolated and the tow force is coupled directly to the frame. However, when the energy management device is moved in a second, generally opposite direction, the energy management device reduces some or all of the force applied to the receiver from being transferred to the vehicle frame.

Abstract: An energy-absorbing system includes a tube made of a continuous material, such as heat-treatable steel. The tube has first and second ring sections connected by an intermediate section. In one aspect, the intermediate section is flared and/or pinched to cause one tube section to predictably telescopingly roll upon impact. In another aspect, one section is annealed to optimize elongation and yield properties to facilitate rolling upon impact. By this arrangement, upon the bumper system receiving a longitudinal impact, the first and second ring sections telescopingly collapse with a predictable and consistent rolling collapse. Methods related to the above are also disclosed.

Abstract: A method comprises steps of providing bar stock, cutting the stock to form a rod-shaped blank, and stamp-forming a ball section on a first end of the blank in a transfer die. The method further includes stamp-forming an apertured flattened section on a second end of the blank to form a final product in the transfer die, and axially striking opposing ends to accurately form a length of the blank. A related transfer die apparatus includes stations for cutting and then stamp-forming a ball section on a first end of the blank, and stamp-forming an apertured flattened section on a second end of the blank to form a final product.

Abstract: A vehicle door beam of relatively small profile and high strength. The door beam is fabricated from a web and includes a beam portion and brackets extending from opposite ends of the beam portion. The beam portion includes two lateral portions of the web rolled inwardly into closed configurations, and the two lateral edges of the lateral portions are welded to the beam portion. In an alternative embodiment, a second web is included in the beam portion and is part of both of the closed configurations.

Abstract: A bumper system for a vehicle comprises a beam having a face and having mounts adapted for mounting to a vehicle frame, and an energy absorber engaging the face and having end sections located outboard of ends of the beam, the energy absorber being made of a structural engineering polymeric material and the end sections having flat top surfaces for forming steps outboard of the ends of the beam.

Abstract: A vehicle bumper beam includes front, rear, top and bottom walls and parallel reinforcement walls that define upper and lower tubes. The front wall includes a vertical section, an angled section, and a bent section on the upper tube. The reinforcement wall supports the angled section below the bent section to provide predictable and desired energy absorption. The angled section preferably includes an angled portion defining a first vertical dimension in the first tube and the vertical section defining a second vertical dimension, with a ratio of the first and second being about 1:3. In one embodiment, the upper and lower tubes are spaced apart.

Abstract: A vehicle door beam of relatively small profile and high strength. The door beam is fabricated from a web and includes a beam portion and brackets extending from opposite ends of the beam portion. The beam portion includes two lateral portions of the web rolled inwardly into closed configurations, and the two lateral edges of the lateral portions are welded to the beam portion. In an alternative embodiment, a second web is included in the beam portion and is part of both of the closed configurations.