Abstract: A system and apparatus is disclosed for controlling a restraining force applied to a panel. The apparatus includes a die, a binder supporting the panel against the die, and a punch used to draw the panel into the die. A restraining element is disposed on one of the die and the binder that engages a surface of the panel and applies a restraining force onto the panel. A strain gauge is disposed inside at least one of the die and the binder that engages a surface of the panel to measure the restraining force applied to the panel. The level of restraining force applied by the restraining element onto the panel is controlled based upon the restraining force measured by the strain gauge.

Abstract: A method for measuring localized stretching of a manufactured part or in a test sample of various materials to identify the fracture strain or strain distribution. The method begins by etching or printing a grid of a plurality of cells on a surface of a blank. Dots of paint are then applied to the surface of the blank that are measured in a pre-forming condition and identified as to the location of the dots relative to the grid. The blank is then formed into a formed part and the dots are measured in one or more cells in a post-forming condition. The size of the dots in the pre-forming condition is compared to the size of the dots in the post-forming condition to determine the extent of stretching in localized areas of the formed part. The method may be repeated for successive operations with different colored dots.

Abstract: An apparatus for de-stacking sheet metal blanks uses electro-magnetic pulses to separate sheet metal blanks from a stack of blanks. A fixture supports an electromagnetic attraction device that includes one or more multi-turn electrical coils and one or more insulated metal screens. The coil is electrically connected to a bank of capacitors. The metal screen is disposed in an electrical insulation material and is retained by the fixture between the coil and the top blank of the stack of blanks. Suction cups perform the primary lifting function and are connected to a vacuum source. The suction cups may be supported by the same fixture or another associated fixture that cooperates with the coil and insulated screen.

Abstract: A system and apparatus is disclosed for controlling a restraining force applied to a panel. The apparatus includes a die, a binder supporting the panel against the die, and a punch used to draw the panel into the die. A restraining element is disposed on one of the die and the binder that engages a surface of the panel and applies a restraining force onto the panel. A strain gauge is disposed inside at least one of the die and the binder that engages a surface of the panel to measure the restraining force applied to the panel. The level of restraining force applied by the restraining element onto the panel is controlled based upon the restraining force measured by the strain gauge.

Abstract: A method for measuring localized stretching of a manufactured part or in a test sample of various materials to identify the fracture strain or strain distribution. The method begins by etching or printing a grid of a plurality of cells on a surface of a blank. Dots of paint are then applied to the surface of the blank that are measured in a pre-forming condition and identified as to the location of the dots relative to the grid. The blank is then formed into a formed part and the dots are measured in one or more cells in a post-forming condition. The size of the dots in the pre-forming condition is compared to the size of the dots in the post-forming condition to determine the extent of stretching in localized areas of the formed part. The method may be repeated for successive operations with different colored dots.

Abstract: An apparatus for de-stacking sheet metal blanks uses electro-magnetic pulses to separate sheet metal blanks from a stack of blanks. A fixture supports an electromagnetic attraction device that includes one or more multi-turn electrical coils and one or more insulated metal screens. The coil is electrically connected to a bank of capacitors. The metal screen is disposed in an electrical insulation material and is retained by the fixture between the coil and the top blank of the stack of blanks. Suction cups perform the primary lifting function and are connected to a vacuum source. The suction cups may be supported by the same fixture or another associated fixture that cooperates with the coil and insulated screen.

Abstract: A method of forming a part and a method of designing a part to be formed from a sheet metal blank is disclosed. The part may be formed from lightweight high-strength material to an extent that would normally exceed the forming limits of the material if the part were attempted to be formed in one step in a multi-part die set. Critical areas including deep pockets and sharp radius areas of the final part are formed from a preform or intermediate shape part. The preform is further formed in a fluid pressure forming process to a final part shape wherein broad radius areas of the preform are formed into deep pockets and sharp corners.