Abstract: A device for incrementally forming a plurality of workpieces includes a frame configured to receive a workpiece, at least one clamp configured to secure the workpiece to the frame, a first sacrificial material layer configured to be secured to at least one surface of the workpiece, and a first forming tool configured to impart a first force directly to the first sacrificial material layer and incrementally form the workpiece to a desired geometry based on a tool path of the first forming tool. The frame, the at least one clamp, the first sacrificial material layer, and the first forming tool are configured to impart a first force directly to the first sacrificial material layer secured to at least one surface of a first workpiece with the first forming tool and incrementally form the first workpiece to a desired geometry based on a tool path of the first forming tool.

Abstract: An apparatus for destacking a blank from a stack of blanks includes an electromagnetic-suction device including a primary suction device and an electromagnetic device, where the primary suction device is integrated with the electromagnetic device. The apparatus includes an auxiliary suction device proximate to the electromagnetic-suction device.

Abstract: A device for incrementally forming a plurality of workpieces includes a frame configured to receive a workpiece, at least one clamp configured to secure the workpiece to the frame, a first sacrificial material layer configured to be secured to at least one surface of the workpiece, and a first forming tool configured to impart a first force directly to the first sacrificial material layer and incrementally form the workpiece to a desired geometry based on a tool path of the first forming tool. The frame, the at least one clamp, the first sacrificial material layer, and the first forming tool are configured to impart a first force directly to the first sacrificial material layer secured to at least one surface of a first workpiece with the first forming tool and incrementally form the first workpiece to a desired geometry based on a tool path of the first forming tool.

Abstract: A method of incrementally forming workpiece is provided by the present disclosure. In one form, the method includes securing a sacrificial material layer to at least one surface of the workpiece, imparting a force directly to the sacrificial material layer with at least one forming tool, and incrementally forming the workpiece to a desired geometry based on a tool path of the forming tool.

Abstract: A method of incrementally forming workpiece is provided by the present disclosure. In one form, the method includes securing a sacrificial material layer to at least one surface of the workpiece, imparting a force directly to the sacrificial material layer with at least one forming tool, and incrementally forming the workpiece to a desired geometry based on a tool path of the forming tool.

Abstract: A tool and method of hemming a panel wherein the tool engages a flange to apply a compressive force with a stop initially preventing a distal end of the flange from moving inwardly. The hemming tool bends the intermediate portion of the flange between the flange bend and the distal end toward the panel. The stop is withdrawn to allow the flange to be progressively formed toward the panel until the distal end is aligned with the intermediate portion.

Abstract: A trim tool for trimming a part having a complex shape. The trim tool defines a plurality of electro-hydraulic cavities that are separated by walls in a lower die of the trim tool. Electrodes are discharged in the electro-hydraulic cavities to drive the panel into engagement with a trim steel edge. The discharge of the electrode severs the panel above the cavity and also across a portion of a wall separating adjacent cavities. Discharging an electrode in an adjacent cavity completes the trim operation above the wall.

Abstract: A trim tool for trimming a part having a complex shape. The trim tool defines a plurality of electro-hydraulic cavities that are separated by walls in a lower die of the trim tool. Electrodes are discharged in the electro-hydraulic cavities to drive the panel into engagement with a trim steel edge. The discharge of the electrode severs the panel above the cavity and also across a portion of a wall separating adjacent cavities. Discharging an electrode in an adjacent cavity completes the trim operation above the wall.

Abstract: A hemming tool for forming a hem securing an outer panel to an inner panel. The hemming tool includes a hemming die that has a first portion of a forming surface with a first coefficient of friction and a second portion that has a second coefficient of friction that is greater than the first portion. A flange on the outer panel is initially engaged by the first surface to begin forming the hem flange toward the inner panel. The flange is engaged by the second hemming surface to continue forming the flange toward the inner panel. A method of hemming a sheet metal assembly including an inner and an outer panel is also disclosed that utilizes the hemming die that has a forming surface with a second coefficient of friction that is greater than the first portion to reduce flange creep and roll-in during a hemming operation.

Abstract: A tool and method of hemming a panel wherein the tool engages a flange to apply a compressive force with a stop initially preventing a distal end of the flange from moving inwardly. The hemming tool bends the intermediate portion of the flange between the flange bend and the distal end toward the panel. The stop is withdrawn to allow the flange to be progressively formed toward the panel until the distal end is aligned with the intermediate portion.

Abstract: A tool and method of hemming a panel wherein the tool engages a flange to apply a compressive force with a stop initially preventing a distal end of the flange from moving inwardly. The hemming tool bends the intermediate portion of the flange between the flange bend and the distal end toward the panel. The stop is withdrawn to allow the flange to be progressively formed toward the panel until the distal end is aligned with the intermediate portion.

Abstract: A tool and method of hemming a panel wherein the tool engages a flange to apply a compressive force with a stop initially preventing a distal end of the flange from moving inwardly. The hemming tool bends the intermediate portion of the flange between the flange bend and the distal end toward the panel. The stop is withdrawn to allow the flange to be progressively formed toward the panel until the distal end is aligned with the intermediate portion.

Abstract: An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die.

Abstract: An electrohydraulic forming (EHF) tool and a method of forming a sheet metal blank in an EHF operation. The tool may include a pair of electrodes and may be filled with a liquid. A high voltage discharge may be produced between the electrodes in a manner that induces a shockwave within the fluid. The shockwave may produce sufficient force within the liquid to form the blank against a die.

Abstract: An electrohydraulic forming (EHF) tool having a pair of electrodes that can be used to generate a shockwave to facilitate forming a sheet metal blank against a forming die. The electrodes may be adjusted during the course of operation. This may be useful should continued use cause their efficiency to drop below a desired threshold.