Abstract: An apparatus for forming a part is provided, which includes a die. The die includes a round orifice, a central mandrel disposed within the round orifice, and a plurality of bridges and a corresponding plurality of portholes between the bridges. The bridges and the portholes extending around the central mandrel. A spacing of the bridges around the mandrel is non-equiangular. The die allows a material to be extruded through the die to form a round, closed geometry tube from the material such that the round, closed geometry tube has non-equiangular welds after emerging from the die.

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 for forming a vehicle component is provided. The method may include heating a blank of 36MnB5 in a furnace to an austenitization temperature, stamping the blank with a die assembly to form a vehicle component and change a microstructure of the blank from austenite to martensite, and responsive to a temperature of the vehicle component being at or below 130° C., removing the vehicle component from the die assembly such that the vehicle component has a yield strength equal to or greater than 1400 MPa. The blank may be retained within the die assembly for a quench time of between five and eleven seconds following the stamping. The method may further include thermo-stabilizing a surface of the die assembly to a predetermined temperature. The stamping may further include applying a pressure of approximately 10 N/mm2 to the blank.

Abstract: A method of manufacturing a metal component includes performing a test stamping process on a test sheet metal blank, generating a strain map of the test sheet metal blank for the test stamping process, generating a lubrication program based on the strain map, applying lubrication to the sheet metal according to the lubrication program, and stamping the sheet metal to form the metal component. The lubrication program is configured to control a lubrication system to apply lubrication to sheet metal in a non-uniform distribution across the sheet metal. The non-uniform distribution correlates to the strain map.

Abstract: A forming die includes a first die component with a male bead and a second die component with a female bead. The male bead and the female bead form a bead with a reverse bead geometry with the male bead having a groove and the female bead having a protrusion complimentary with the groove such that the protrusion is aligned with the groove when the male bead extends into the female bead. The male bead includes a push surface, a pair of sidewalls extending from the push surface to a main surface of the first die component, and the groove extends inwardly into the rib. And the female bead includes a stop surface and a pair of sidewalls extending from the stop surface to a main surface of the second die component, and the protrusion extends outwardly from the stop surface into the female bead.

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 forming die includes a first die component with a male bead and a second die component with a female bead. The male bead and the female bead form a bead with a reverse bead geometry with the male bead having a groove and the female bead having a protrusion complimentary with the groove such that the protrusion is aligned with the groove when the male bead extends into the female bead. The male bead includes a push surface, a pair of sidewalls extending from the push surface to a main surface of the first die component, and the groove extends inwardly into the rib. And the female bead includes a stop surface and a pair of sidewalls extending from the stop surface to a main surface of the second die component, and the protrusion extends outwardly from the stop surface into the female bead.

Abstract: A method of quenching a press hardenable steel (PHS) is provided. The method includes preparing a die having a material with a thermal conductivity of at least 40W/(m·K) and placing a blank within the die and simultaneously hot stamping and quenching the blank at a heat transfer coefficient of at least 2,950W/(m2·K). In one form, the step of hot stamping the blank is carried out with greater than 20 MPa of contact pressure between the die and the blank. In another form, the step of hot stamping the blank is carried out with 31 MPa of contact pressure between the die and the blank.

Abstract: A self-piercing rivet (SPR) includes a head portion and a shaft extending from the head portion. The shaft defines a hollow bore and a sidewall surrounding the hollow bore. The sidewall has a reduced thickness towards a distal end portion of the shaft to define a cutting edge on a distal end tip of the shaft, and the SPR defines a circumferential groove disposed at least partially around the shaft and extending into the sidewall.

Abstract: A method of separating a blank from a stack of blanks is provided and includes grasping a first blank and moving the first blank away from a plurality of blanks. At least one additional blank from the plurality of blanks is adhered to the first blank to form a sub-stack of blanks and at least one impulse electrically generated force (EGF) is applied to separate the at least one additional blank from the first blank. The first blank may be grasped by a device with a force F1, and the at least one impulse EGF may be less than the force F1. Also, the at least one impulse EGF may be applied to separate the at least one additional blank from the first blank by passing a pulse of current through an EGF generator positioned adjacent the first blank and inducing an EGF within the plurality of blanks.

Abstract: A die apparatus including a first die element, a plurality of second die elements, a plurality of actuators, and a controller is provided. Each of the plurality of actuators is mounted to one of the plurality of second die elements. The controller is programmed to activate the actuators to contact and compress portions of a blank disposed between the die elements at separate pressures to influence microstructure forming for one of a geometry transition region, a deformation region, and a joining region. One of the separate pressures applied to one of the portions of the blank may be approximately 5 N/mm2 or less to form a soft strength zone. The pressure of approximately 5 N/mm2 or less may be applied to the one of the portions of the blank for approximately one to two seconds.

Abstract: A method of quenching a press hardenable steel is provided. The method includes an initial step of die quenching a part stamped within a stamping die followed by a partial quenching after the initial step of die quenching. In various methods, the press hardenable steel is a 36MnB5 grade steel and/or the initial step of die quenching is performed at a temperature of approximately 200° C.±10° C. in a die configured for 36MnB5 grade steel. At least one method further includes opening the die followed by the partial quenching, the partial quenching comprising spraying a cooling liquid onto the part to reduce a temperature of the part below approximately 130° C.±10° C., with the option of spraying to reduce the temperature of the part below approximately 100° C.±10° C.

Abstract: The present disclosure is generally directed toward a high volume manufacturing method for forming high strength aluminum parts. The method includes acquiring material blanks that are made of 7xxx series aluminum alloy, heating the blanks to a solvus temperature of the material, and stamping and quenching the heated blanks to form multiple parts. The parts are cooled to a second temperature lower than the solvus temperature during the quenching operation. The method further includes performing one or more structural modifications of the parts within a set time period that is less than or equal to 24 hours. The method further includes racking the parts with a gap defined between two adjacent parts, artificially aging the parts with an industrial oven, and pretreating the parts with a chemical solution.

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 producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discreet layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Abstract: A die apparatus including a first die element, a plurality of second die elements, a plurality of actuators, and a controller is provided. Each of the plurality of actuators is mounted to one of the plurality of second die elements. The controller is programmed to activate the actuators to contact and compress portions of a blank disposed between the die elements at separate pressures to influence microstructure forming for one of a geometry transition region, a deformation region, and a joining region. One of the separate pressures applied to one of the portions of the blank may be approximately 5 N/mm2 or less to form a soft strength zone. The pressure of approximately 5 N/mm2 or less may be applied to the one of the portions of the blank for approximately one to two seconds.

Abstract: An apparatus for forming a part is provided, which includes a die. The die includes a round orifice, a central mandrel disposed within the round orifice, and a plurality of bridges and a corresponding plurality of portholes between the bridges. The bridges and the portholes extending around the central mandrel. A spacing of the bridges around the mandrel is non-equiangular. The die allows a material to be extruded through the die to form a round, closed geometry tube from the material such that the round, closed geometry tube has non-equiangular welds after emerging from the die.

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 forming a part includes extruding a billet through a die, forming a round, closed geometry tube from the billet, and hydroforming the round, closed geometry tube. The extrusion die contains an orifice with a central mandrel, a plurality of bridges, and a corresponding plurality of portholes between the bridges. A spacing of the bridges around the mandrel is non-equiangular. As a result, the round, closed geometry tube has non-equiangular welds after emerging from the die.

Abstract: A method of evaluating a sheet metal stamping simulation is provided. The method may include defining elements of a finite-element mesh representing a stamped panel, operating on the elements to simulate deformation of the panel during stamping to generate, for each of the elements, incremental differential major and minor plastic strain values, applying a weighting factor to temporally adjacent pairs of the values to generate smoothed values, deriving, from the smoothed values and for each of the elements, a plurality of plastic strain incremental ratios representing plastic flow direction of the elements during the deformation, and altering colors of a map based on the ratios to represent changes in severity of plastic deformation of the stamped panel.