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: Apparatus and methods are disclosed for applying electromagnetic force (EMF) to flanging and hemming metal panels to form a hemmed panel assembly. First and second apparatus and method steps use a translating EMF coil to flange a sheet and to finish a hem by progressive non-planar bending. An alternate embodiment uses EMF hemming for difficult-to-hem portions of a flange and optionally precedes this with conventional hemming of straight hem portions.

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 bending apparatus for bending and transporting an aluminum metal sheet. The bending apparatus includes a central retaining portion that has gripping elements mounted on the central retaining portion for retaining an aluminum metal sheet. There is also included a bending mechanism that is mounted to the central retaining portion. The bending mechanism is capable of axial movement in relation to a central axis of the central retaining portion for imparting a curvature to an aluminum metal sheet. There is also included a method of stretch forming an aluminum metal sheet including the steps of heating an aluminum metal sheet in an oven, transferring the heat of an aluminum sheet to a hot forming tool, bending the heated aluminum sheet during the transfer step to conform the sheet to a shape of the hot forming tool, and then placing the bent metal sheet in the hot forming tool and forming an A-shaped part.

Abstract: A method is disclosed for heating a cold worked sheet of superplastically formable metal composition to recrystallize its microstructure to a formable condition and/or to heat the sheet to a temperature for an immediate forming operation. The sheet is placed between two electrical resistance heated platens maintained at a suitable temperature for recrystallizing and/or heating the metal sheet through its side surfaces. In a preferred embodiment a critical gap is maintained between the platens and the sheet to permit rapid conductive heating of the expanding sheet without marring its surfaces.

Abstract: A method is disclosed for heating a cold worked sheet of superplastically formable metal composition to recrystallize its microstructure to a suitably formable condition and further to heat the sheet to a temperature for an immediate forming operation. The method utilizes a combination of hot air convection heating and infrared radiation to rapidly accomplish the heating. High temperature infrared heating elements provide most of the energy during an initial high heating rate phase and then those elements are shut off and heating is completed with controlled temperature hot air to prevent overheating of the sheet metal.

Abstract: A bending apparatus for bending and transporting an aluminum metal sheet. The bending apparatus includes a central retaining portion that has gripping elements mounted on the central retaining portion for retaining an aluminum metal sheet. There is also included a bending mechanism that is mounted to the central retaining portion. The bending mechanism is capable of axial movement in relation to a central axis of the central retaining portion for imparting a curvature to an aluminum metal sheet.

Abstract: A bending apparatus for bending and transporting an aluminum metal sheet. The bending apparatus includes a central retaining portion that has gripping elements mounted on the central retaining portion for retaining an aluminum metal sheet. There is also included a bending mechanism that is mounted to the central retaining portion. The bending mechanism is capable of axial movement in relation to a central axis of the central retaining portion for imparting a curvature to an aluminum metal sheet. There is also included a method of stretch forming an aluminum metal sheet including the steps of heating an aluminum metal sheet in an oven, transferring the heat of an aluminum sheet to a hot forming tool, bending the heated aluminum sheet during the transfer step to conform the sheet to a shape of the hot forming tool, and then placing the bent metal sheet in the hot forming tool and forming an A-shaped part.

Abstract: A method is disclosed for heating a cold worked sheet of superplastically formable metal composition to recrystallize its microstructure to a formable condition and/or to heat the sheet to a temperature for an immediate forming operation. The sheet is placed between two electrical resistance heated platens maintained at a suitable temperature for recrystallizing and/or heating the metal sheet through its side surfaces. In a preferred embodiment a critical gap is maintained between the platens and the sheet to permit rapid conductive heating of the expanding sheet without marring its surfaces.

Abstract: A method is disclosed for heating a cold worked sheet of superplastically formable metal composition to recrystallize its microstructure to a suitably formable condition and further to heat the sheet to a temperature for an immediate forming operation. The method utilizes a combination of hot air convection heating and infrared radiation to rapidly accomplish the heating. High temperature infrared heating elements provide most of the energy during an initial high heating rate phase and then those elements are shut off and heating is completed with controlled temperature hot air to prevent overheating of the sheet metal.

Abstract: A bending apparatus for bending and transporting an aluminum metal sheet. The bending apparatus includes a central retaining portion that has gripping elements mounted on the central retaining portion for retaining an aluminum metal sheet. There is also included a bending mechanism that is mounted to the central retaining portion. The bending mechanism is capable of axial movement in relation to a central axis of the central retaining portion for imparting a curvature to an aluminum metal sheet.

Abstract: A method is disclosed for forming a hem flange in an aluminum alloy sheet during the forming of the sheet into a panel that is intended to be attached to a second panel by hemming. The hem flange is formed by fluid pressure over a small radius tool portion to bend the flange from the sheet material and stretch the flange material below the bend to form a thinned hemline valley in the material. The original bend and thinned valley cooperate during the folding of the flange around the second panel to form a flat pinched hem without cracking or fracturing the flange material.

Abstract: A method is disclosed for forming a hem flange in an aluminum alloy sheet during the forming of the sheet into a panel that is intended to be attached to a second panel by hemming. The hem flange is formed by fluid pressure over a small radius tool portion to bend the flange from the sheet material and stretch the flange material below the bend to form a thinned hemline valley in the material. The original bend and thinned valley cooperate during the folding of the flange around the second panel to form a flat pinched hem without cracking or fracturing the flange material.

Abstract: The superplastic forming of suitable metal alloy sheets into strong components, such as automobile body structures or panels, is improved and accomplished faster by simultaneously forming two or more substantially identical, relatively thin sheets, preferably about 2 mm or less in thickness, rather than a single sheet of the same overall thickness. For example, two or more layers of thin AA5083 sheets can be stretched formed together at about 500° C. with greater deformation and elongation than a single sheet of comparable thickness.

Abstract: The superplastic forming of suitable metal alloy sheets into strong components, such as automobile body structures or panels, is improved and accomplished faster by simultaneously forming two or more substantially identical, relatively thin sheets, preferably about 2 mm or less in thickness, rather than a single sheet of the same overall thickness. For example, two or more layers of thin AA5083 sheets can be stretched formed together at about 500° C. with greater deformation and elongation than a single sheet of comparable thickness.