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 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: An tool for the incremental forming of material sheeting is disclosed. The tool comprises a forming tip, a shank, and an interface adapter positioned between the forming tip and the shank. The forming tip has a diameter and the shank has a diameter. The diameter of the forming tip is greater than the diameter of the shank. The forming tip may be of a variety of configurations. The forming tip may be donut-shaped. The donut-shaped tip may have a recessed area formed therein. The recessed area may be frustoconically shaped. As an alternative to the forming tip being donut-shaped, the forming tip may be made up of at least two forming spheres. An adapter is provided to which the spheres may be attached either directly or by arms. The diameters of the spheres may be the same or may be different diameters.

Abstract: A vehicle model including main and secondary modules is provided. The vehicle module may also include vehicle components, a frame, a camera system, and a controller. The vehicle components are operably connected to the modules. The frame supports the modules and components and defines a 3D coordinate system including identifiable reference points. The camera system is arranged with the frame to capture activity within the 3D coordinate system. The controller is in communication with, and configured to direct operation of, the modules, components, and camera system based on the identifiable reference points and accessible vehicle CAD data. The vehicle components may comprise a subject platform located adjacent to, detached from, and integrated to function with the modules. The subject platform may be configured to vertically adjust between a plurality of positions for simulating ground outside a vehicle.

Abstract: An tool for the incremental forming of material sheeting is disclosed. The tool comprises a forming tip, a shank, and an interface adapter positioned between the forming tip and the shank. The forming tip has a diameter and the shank has a diameter. The diameter of the forming tip is greater than the diameter of the shank. The forming tip may be of a variety of configurations. The forming tip may be donut-shaped. The donut-shaped tip may have a recessed area formed therein. The recessed area may be frustoconically shaped. As an alternative to the forming tip being donut-shaped, the forming tip may be made up of at least two forming spheres. An adapter is provided to which the spheres may be attached either directly or by arms. The diameters of the spheres may be the same or may be different diameters.

Abstract: In one or more embodiments, a composite die includes a die face defining a protrusion and including a first metal, and a die base supporting the die face, the die base including a housing, a first filler positioned within the housing and contacting the protrusion, and a bridging member reinforcing the housing, the housing including a second metal different than the first metal.

Abstract: A friction stir spot welding tool and a self-piercing riveting tool are disclosed for joining parts. The parts are clamped between a head and anvil support of the friction stir spot welding tool or the self-piercing riveting tool. A plurality of clamping and heating modules are attached to an attachment fixture on the head and the anvil support that heats the area around the pin of the friction stir spot welding tool or self-piercing riveting tool prior to and during the joining operation.

Abstract: In one or more embodiments, a composite die includes a die face defining a protrusion and including a first metal, and a die base supporting the die face, the die base including a housing, a first filler positioned within the housing and contacting the protrusion, and a bridging member reinforcing the housing, the housing including a second metal different than the first metal.

Abstract: A vehicle model including main and secondary modules is provided. The vehicle module may also include vehicle components, a frame, a camera system, and a controller. The vehicle components are operably connected to the modules. The frame supports the modules and components and defines a 3D grid including identifiable reference points. The camera system is arranged with the frame to capture activity within the 3D grid. The controller is in communication with, and configured to direct operation of, the modules, components, and camera system based on the identifiable reference points and accessible vehicle CAD data. The vehicle components may comprise a subject platform located adjacent to, detached from, and integrated to function with the modules. The subject platform may be configured to vertically adjust between a plurality of positions for simulating ground outside a vehicle.

Abstract: In one embodiment, a vehicle model is disclosed. The vehicle model includes a main vehicle module including a primary base and a number of components. The number of main vehicle module components is moveably mounted to the main vehicle module primary base. The vehicle model also includes a secondary vehicle module including a number of components. The main vehicle module and secondary vehicle modules are relatively positionable relative to one another to obtain a first and second vehicle configuration. The first and second vehicle configurations are different from each other.

Abstract: An incremental forming machine binder is provided that has a blank holding opening that may be subdivided into smaller blank holding openings. The opening is subdivided by one or more clamping modules that are connected by connecting modules to each other and the frame. Clamps are attached to the clamping modules to clamp blanks in the blank holding openings. Multiple blanks may be secured to the binder for incremental forming.

Abstract: A method of incrementally forming a workpiece. The method includes incrementally forming a first monotonic wrap surface in a first direction and incrementally forming a second wrap surface in a second direction disposed opposite the first direction.

Abstract: An incremental forming machine binder is provided that has a blank holding opening that may be subdivided into smaller blank holding openings. The opening is subdivided by one or more clamping modules that are connected by connecting modules to each other and the frame. Clamps are attached to the clamping modules to clamp blanks in the blank holding openings. Multiple blanks may be secured to the binder for incremental forming.

Abstract: A friction stir spot welding tool and a self-piercing riveting tool are disclosed for joining parts. The parts are clamped between a head and anvil support of the friction stir spot welding tool or the self-piercing riveting tool. A plurality of clamping and heating modules are attached to an attachment fixture on the head and the anvil support that heats the area around the pin of the friction stir spot welding tool or self-piercing riveting tool prior to and during the joining operation.

Abstract: A system and method for incrementally forming a workpiece. A first manipulator is configured to move a first tool in multiple directions along a first surface of a workpiece. A second manipulator is configured to move a second tool in multiple directions along a second surface of the workpiece. The first and second tools move along first and second predetermined paths of motion and exert force to form the workpiece.

Abstract: A method of incrementally forming a workpiece. The method includes determining a desired workpiece geometry, generating a tool path in which a feature is formed outwardly from a point that is disposed a maximum distance from a reference position, and incrementally forming the workpiece.

Abstract: A method of incrementally forming a workpiece. The method includes determining a desired workpiece geometry, generating a tool path in which a feature is formed outwardly from a point that is disposed a maximum distance from a reference position, and incrementally forming the workpiece.

Abstract: A method of incrementally forming a workpiece. The method includes incrementally forming a first monotonic wrap surface in a first direction and incrementally forming a second wrap surface in a second direction disposed opposite the first direction.

Abstract: A system and method for incrementally forming a workpiece. A first manipulator is configured to move a first tool in multiple directions along a first surface of a workpiece. A second manipulator is configured to move a second tool in multiple directions along a second surface of the workpiece. The first and second tools move along first and second predetermined paths of motion and exert force to form the workpiece.

Abstract: In one embodiment, a vehicle model is disclosed. The vehicle model includes a main vehicle module including a primary base and a number of components. The number of main vehicle module components is moveably mounted to the main vehicle module primary base. The vehicle model also includes a secondary vehicle module including a number of components. The main vehicle module and secondary vehicle modules are relatively positionable relative to one another to obtain a first and second vehicle configuration. The first and second vehicle configurations are different from each other.