Abstract: One embodiment includes a method for forming panels in which a particular shaping of the addendum contours of the formed panel to provide the functionality of the cooling fixture.

Abstract: A quick plastic forming (QPF) tool is provided in which a thermal gap is created that reduces or eliminates some of the conductive heat loss paths when the QPF tool is in an open position during part removal or sheet loading. By reducing conductive heat loss, a more precise temperature control for the QPF tool from manufacturing cycle to manufacturing cycle may be realized. The QPF tool may also have a thermal gap when the tool is placed in a semi-open position during idle times. The QPF tool may also include components for creating the thermal gap when the QPF tool is moved to the open position and control the lateral movement of the part forming section of the QPF tool as the part is moved between the open position and the closed position.

Abstract: A quick plastic forming (QPF) tool is provided in which a thermal gap is created that reduces or eliminates some of the conductive heat loss paths when the QPF tool is in an open position during part removal or sheet loading. By reducing conductive heat loss, a more precise temperature control for the QPF tool from manufacturing cycle to manufacturing cycle may be realized. The QPF tool may also have a thermal gap when the tool is placed in a semi-open position during idle times. The QPF tool may also include components for creating the thermal gap when the QPF tool is moved to the open position and control the lateral movement of the part forming section of the QPF tool as the part is moved between the open position and the closed position.

Abstract: The present invention relates to a heating and forming apparatus for sheet material and method for rapid heating and shaping of sheet material. The apparatus comprises a first and second respectively movable forming dies, with the first forming die having a forming surface and defining a cavity with the second forming die. The apparatus is adaptable to receive a sheet material positionable within the cavity. A heating mechanism is placed within the cavity to heat the sheet material. The forming surface of the first forming die is not substantially heated. A pressurization mechanism is in communication with the cavity to move the sheet material into conformity with the forming surface of the first die. An improvement in the process of stretch forming a sheet material into a product by using quick plastic forming (QPF) or superplastic forming (SPF) is provided.

Abstract: Work hardenable aluminum alloy sheet material is progressively stamped to a final stamped shape in a succession of stamping operations. A blank sheet of annealed starting material is stamped into a least a first preform shape between heated stamping tools to form a preform shape and subsequently anneal the worked preform shape. After one or more annealed preform shapes have been progressively attained, the last preform shape is cooled, if necessary, and stamped to its final stamped shape between unheated stamping tools.

Abstract: Method of preforming and forming a sheet metal article from a preheated blank of sheet metal uses opposing dies including a punch having a punch surface defining a final configuration for the article and a cavity die having a cavity surface defining a preform configuration. The blank is placed between the dies and has a first side surface facing the cavity die and a second side surface facing the punch. A vacuum is applied to the first side of the blank to draw and shape the blank into the cavity die to a preform configuration conforming to the cavity surface. The punch and the cavity die are then closed toward one another and gas pressure is then applied to the first side surface of the blank to press the second side surface against the punch surface to the finish configuration.

Abstract: An apparatus for forming blanks having two thicknesses separated by a blank step includes a forming tool defining a binder surface that is characterized by a tool step, a first region on a first side of the tool step, a second region on a second side of the tool step, and a bead segment having a surface contiguous with the second region. The bead segment is configured to pinch material from a blank into any gap created between the tool step and the blank step caused by misalignment of the blank in the tool, thereby ensuring an effective seal to form the blank against a forming surface.

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: Various embodiments of roller hemming apparatus and methods are disclosed including one wherein multiple rollers are carried on a single mount to hem a flange in a single pass, another including induction heating and air quenching means movable with a roller to anneal the flange just prior to hem forming, and another in which friction from a rotatably driven roller heats the flange to reduce bending stresses during hemming of the flange.

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 press and tooling apparatus for forming a preheated blank includes a heated upper tool and an opposing heated lower tool mounted within the press for relative closing movement to press the preheated blank there between. A binder ring assembly surrounds the lower tool and is mounted on the press for movement relative to the lower tool so at to bind the preheated blank to the upper tool in air tight sealing relationship in readiness for closure of the tools and application of pressurized gas to force the blank into contact with the upper tools. The binder ring assembly includes an upper ring that is heated so as to prevent the cooling of the preheated blank, and a lower ring that supports the upper ring and is fixedly connected to the upper ring by spaced apart connectors so as to minimize the heat transfer path from the heated upper ring to the lower ring.

Abstract: A cleaning apparatus for removing metallic buildup from forming surfaces of metal forming dies while the dies are in a press and operating at elevated temperatures. The cleaning apparatus includes a programmable positioner having a robotic arm with an end effector carrying a brush assembly. The brush assembly includes a rotary drive motor rotatably carrying a metallic wire brush. The brush has a plurality of radially extending plain carbon steel bristles having tips adapted for removing metallic buildup from the forming surfaces of dies. The positioner operates to move the rotatable wire brush in a predetermined path that engages the brush with the forming surfaces of the dies for sweeping and cleaning metallic buildup from the forming surfaces.

Abstract: The present invention relates to a heating and forming apparatus for sheet material and method for rapid heating and shaping of sheet material. The apparatus comprises a first and second respectively movable forming dies, with the first forming die having a forming surface and defining a cavity with the second forming die. The apparatus is adaptable to receive a sheet material positionable within the cavity. A heating mechanism is placed within the cavity to heat the sheet material. The forming surface of the first forming die is not substantially heated. A pressurization mechanism is in communication with the cavity to move the sheet material into conformity with the forming surface of the first die. An improvement in the process of stretch forming a sheet material into a product by using quick plastic forming (QPF) or superplastic forming (SPF) is provided.

Abstract: Method of preforming and forming a sheet metal article from a preheated blank of sheet metal uses opposing dies including a punch having a punch surface defining a final configuration for the article and a cavity die having a cavity surface defining a preform configuration. The blank is placed between the dies and has a first side surface facing the cavity die and a second side surface facing the punch. A vacuum is applied to the first side of the blank to draw and shape the blank into the cavity die to a preform configuration conforming to the cavity surface. The punch and the cavity die are then closed toward one another and gas pressure is then applied to the first side surface of the blank to press the second side surface against the punch surface to the finish configuration.

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 press and tooling apparatus for forming a preheated blank includes a heated upper tool and an opposing heated lower tool mounted within the press for relative closing movement to press the preheated blank there between. A binder ring assembly surrounds the lower tool and is mounted on the press for movement relative to the lower tool so at to bind the preheated blank to the upper tool in air tight sealing relationship in readiness for closure of the tools and application of pressurized gas to force the blank into contact with the upper tools. The binder ring assembly includes an upper ring that is heated so as to prevent the cooling of the preheated blank, and a lower ring that supports the upper ring and is fixedly connected to the upper ring by spaced apart connectors so as to minimize the heat transfer path from the heated upper ring to the lower ring.

Abstract: A hot blow-forming apparatus includes opposed and complementary forming tools adapted for hot blow forming a surface of a heated sheet-metal workpiece against a forming surface of one of the tools. The tools are also adapted to close upon and grip a peripheral edge of the workpiece and perform work on a central portion of the workpiece to produce a formed panel. The tools incorporate an improved extraction apparatus, which includes a plurality of opposed and complementary spring-loaded extractor pads. Opposed extractor pads are spring-loaded to different levels so as to apply spring-load differentials therebetween and thereby apply different extraction forces in different locations of the resultant formed panel for distortion-free removal of the formed panel from the working surfaces of the tooling.

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 method of quick-plastic-forming a component from a sheet metal blank in multiple forming stages of single-action tooling along a transfer line. The blank is transferred from a prebending station to a preforming station along the transfer line, wherein the blank is preformed by a single-action forming tool into a preform blank. The preform blank is then transferred from the preforming station to a finish-forming station along the transfer line, wherein the blank is finish-formed by a single-action forming tool into the component. The component is transferred from the finish-forming station to a cooling station along the transfer line. The transfer steps are carried out by a reciprocating transfer mechanism that simultaneously transfers the blanks and component from station to station along the transfer line.

Abstract: The distortion-free removal of a heat softened sheet metal part from a heated forming surface is enabled by the elevation of lift pads in the forming surface. Strategically located and sized pads are recessed in the forming surface of the hot forming tool and the pads are part of the forming surface. At the completion of the stretch forming, or other hot forming, of a sheet metal blank on the forming surface, the pads are lifted in unison, without rotating them, on lift posts by a suitable lift mechanism to carefully and uniformly strip the flexible part from the hot forming surface.