Abstract: A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

Abstract: A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

Abstract: A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

Abstract: A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

Abstract: A method of assembling vehicle-body components includes positioning a first component on a second component. The first component has a different coefficient of thermal expansion than the second component and one of the first and second components defines a slot. The method also includes loosely installing a bolt though the slot and the first and second components, and creating a joint in the first and second components. The method further includes heating the first and second components, which causes the first and second components to move relative to each other due to thermal expansion in response to the heating. This movement causes the joint to fail. The method also includes tightening the bolt.

Abstract: A marking system for a rolled metal coil to provide markings containing data about material properties within the metal proximate the markings. The material property data may be used for allocating blanks from the coil for different vehicle body stampings. A monitoring device may be configured to provide material property data of metal during formation of a coil. A marking device may be configured to provide a 2D-matrix as the marking on a surface of the coil. A controller may be programmed to, in response to receiving the data, utilize the marking device to provide the 2D-matrix containing the material property data on the coil proximate a location of the material property. The 2D-matrix may also allow for the traceability of a finished part back to the coil it was blanked and subsequently formed from.

Abstract: A method of assembling vehicle-body components includes positioning a first component on a second component. The first component has a different coefficient of thermal expansion than the second component and one of the first and second components defines a slot. The method also includes loosely installing a bolt though the slot and the first and second components, and creating a joint in the first and second components. The method further includes heating the first and second components, which causes the first and second components to move relative to each other due to thermal expansion in response to the heating. This movement causes the joint to fail. The method also includes tightening the bolt.

Abstract: A marking system for a rolled metal coil to provide markings containing data about material properties within the metal proximate the markings. The material property data may be used for allocating blanks from the coil for different vehicle body stampings. A monitoring device may be configured to provide material property data of metal during formation of a coil. A marking device may be configured to provide a 2D-matrix as the marking on a surface of the coil. A controller may be programmed to, in response to receiving the data, utilize the marking device to provide the 2D-matrix containing the material property data on the coil proximate a location of the material property. The 2D-matrix may also allow for the traceability of a finished part back to the coil it was blanked and subsequently formed from.

Abstract: An automotive door panel is disclosed. The automotive door panel comprises an outer panel, a bezel, a handle and in inner reinforcement. The outer panel has a depression formed on an outside surface surrounding a handle opening. The bezel seats within the depression of the door panel. The handle is mounted to the bezel and includes an attachment member in a YZ axis. The inner reinforcement member has a mounting flange oriented in the YZ axis. A fastener extends through the mounting flange in an X-direction and connects to the attachment member.

Abstract: A method is provided for selecting a heat treated aluminum sheet for use in a manufacturing process. The aluminum sheet is tested for an initial strength value before being stored for a period of time. A subsequent strength value of the aluminum sheet is calculated after the period of time has elapsed. The aluminum sheet is selected for use in the manufacturing process if the subsequent strength value is within a predetermined range.

Abstract: A manufacturing process including a quality control procedure for verifying the completion of forming processes, heat treating and chemically treating parts. Sheet formed blanks, tubular blanks, extrusions and casting are traced through a manufacturing process from the time the parts are received. Metallurgical data relating to parts as received is recorded and marked on the parts. Forming data, heat treating data and chemical treating data may also be recorded by scanning and marking parts throughout the manufacturing process.

Abstract: A manufacturing process including a quality control procedure for verifying the completion of forming processes, heat treating and chemically treating parts. Sheet formed blanks, tubular blanks, extrusions and casting are traced through a manufacturing process from the time the parts are received. Metallurgical data relating to parts as received is recorded and marked on the parts. Forming data, heat treating data and chemical treating data may also be recorded by scanning and marking parts throughout the manufacturing process.

Abstract: A method and tool for forming a hem flange pre-hem and a final hem on a sheet metal panel wherein elastomeric tooling elements are used to apply radial compression during a forming operation. The elastomeric tooling elements are compressed and apply pressure to a side of the sheet metal panel, for example an aluminum panel, that is stretched during a forming process step. A foil layer may be placed between the sheet metal blank and the elastomeric tooling element to reduce friction and further improve forming performance.

Abstract: A method and tool for forming a hem flange pre-hem and a final hem on a sheet metal panel wherein elastomeric tooling elements are used to apply radial compression during a forming operation. The elastomeric tooling elements are compressed and apply pressure to a side of the sheet metal panel, for example an aluminum panel, that is stretched during a forming process step. A foil layer may be placed between the sheet metal blank and the elastomeric tooling element to reduce friction and further improve forming performance.

Abstract: An automotive door assembly (10) includes an inner door (30) having an inner panel (40). The inner panel (40) has a first seat (44) and a second seat (46) integrally formed therein. The first seat (44) has a first side member (50) fixedly attached thereto for separating an exterior of the door assembly (10) from a door cavity thereof. The first side member (50) also reinforces the automotive door assembly (10). Likewise, the second seat (46) a second side member (90) has fixedly attached thereto for separating the exterior of the door assembly (10) from the door cavity thereof. The second side member (90) also reinforces the automotive door assembly (10). The inner panel (40), the first side member (50), and the second side member (90) have an outer door (18) attached thereto for enclosing the door cavity.

Abstract: An automotive door assembly (10) includes an inner door (30) having an inner panel (40). The inner panel (40) has a first seat (44) and a second seat (46) integrally formed therein. The first seat (44) has a first side member (50) fixedly attached thereto for separating an exterior of the door assembly (10) from a door cavity thereof. The first side member (50) also reinforces the automotive door assembly (10). Likewise, the second seat (46) a second side member (90) has fixedly attached thereto for separating the exterior of the door assembly (10) from the door cavity thereof. The second side member (90) also reinforces the automotive door assembly (10). The inner panel (40), the first side member (50), and the second side member (90) have an outer door (18) attached thereto for enclosing the door cavity.

Abstract: An automotive door assembly (10) includes an inner door (30) having an inner panel (40). The inner panel (40) has a first seat (44) and a second seat (46) integrally formed therein. The first seat (44) has a first side member (50) fixedly attached thereto for separating an exterior of the door assembly (10) from a door cavity thereof. The first side member (50) also reinforces the automotive door assembly (10). Likewise, the second seat (46) a second side member (90) has fixedly attached thereto for separating the exterior of the door assembly (10) from the door cavity thereof. The second side member (90) also reinforces the automotive door assembly (10). The inner panel (40), the first side member (50), and the second side member (90) have an outer door (18) attached thereto for enclosing the door cavity.

Abstract: An apparatus for trimming scrap from a blank 10 is provided including a clamping pad 12 holding a blank 14 against a steady blade 16. A moving blade 18 with a radius 24 works in combination with a support element 30,in communication with the scrap 26, to reduce defects in the blank 14 associated with the trimming process.