Abstract: A manufacturing method forms components having a desired shape. A contoured surface is defined for a forming tool for forming a metal blank into the desired shape, wherein respective portions of the metal blank flow over the contoured surface during forming. An intrinsic material flow pattern resulting from the contoured surface is compared to a desired flow in order to identify regions of the contoured surface having an insufficient flow that creates areas in the formed metal blank receiving less than a desired amount of metal. A surface microtexture is applied onto the contoured surface in a pattern selected to increase metal flow along the identified regions by providing a friction in the identified regions that is reduced relative to adjacent regions of the contoured surface.

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: The stamping of a metal sheet within a stamping die is simulated. The die includes a drawbead running perpendicular to a draw direction. A plurality of successive states are generated for iteratively representing the metal sheet from a blank shape to a final stamped shape. The drawbead is represented as a two-dimensional flat band within a model of the stamping die. Forces acting on the metal sheet are calculated at each successive state to define a next successive state. The calculating step includes a restraining force of the drawbead acting on the metal sheet calculated in response to a predetermined function of a length of the metal sheet engaged in the flat band in respective states. The particular width and location of the flat band achieve improved accuracy of estimating the restraining force.

Abstract: A computer-implemented method for recommending one or more materials used in designing and manufacturing parts may include receiving data from at least three data sources. The data sources may include a sourcing, manufacturing, and design data source. The data source data may be standardized to obtain a collection of data including a dataset of materials for consideration in recommending one or more materials for use in one or more parts. The method may also include receiving optimization metrics and constraints for the dataset of materials. Optimization values for each material based on the dataset of materials and the one or more optimization metrics may be determined. An optimization algorithm on each material may be performed based at least on the optimization values and the constraints to obtain one or more recommended materials from the dataset of materials for use in a design of one or more parts.

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 conducting vehicle usage data analysis is provided. The method includes providing usage data about at least one vehicle to a database. The usage data may be analyzed and compared to a member of a set of vehicle development models to determine whether to update a vehicle development model. The usage data may also be analyzed to determine whether to transmit a communication to a vehicle.

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: Various embodiments may include determining a material utilization for one or more assemblies having a plurality of parts. Offal data for one or more parts comprising one or more part assemblies and a blank material utilization status for each of the one or more part assemblies may be received. The blank material utilization status for the one or more part assemblies may be based on a blank material utilization status for each of the one or more parts. The offal data may be standardized to obtain standardized offal data. One or more offal utilization assignments for the part assemblies having a plurality of parts may be determined based on the standardized offal data and the blank material utilization status for the part assemblies. The offal utilization assignments may then be transmitted for assignment to the one or more part assemblies.

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 may include incrementally forming a stiffening feature on the workpiece and incrementally forming a part on the workpiece. A gap between forming tools may be decreased to reform the part.

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: In one or more embodiments, a weldability of a stack-up for use in vehicle part production may be determined. The determination may include receiving general stack-up information, welding standards data for forming a stack-up, and one or more inputs defining one or more stack-up design variables. Additionally, standardized stack-up information may be generated based on the general stack-up information, the one or more design variables, and the welding standards data. Furthermore, historical welding data may be received for predicting a weldability of the stack-up. Predictive logic may be applied to the standardized stack-up information based on the historical welding data to obtain one or more weldability predictions for the stack-up. The one or more weldability predictions may be transmitted for use in vehicle part production.

Abstract: Various embodiments may include a computerized system and method for determining a selection of technologies or processes for use in part production. A dataset of technologies or processes may be considered and standardized. Generic CAD models may be generated from the standardized dataset. Optimization metrics for each generic CAD model may be received. Data from a sourcing, a manufacturing and a design data source may also be received. An optimization algorithm may be used for each generic CAD model based on the optimization metrics and the data from the data sources. One or more optimized CAD models may be generated and one or more optimized technologies or processes for use in part manufacturing may be obtained. The optimized technologies or processes may be based on the one or more optimized CAD models. The optimized technologies or processes may be transmitted for selection and use in producing manufactured parts.

Abstract: A computer-implemented method for recommending one or more materials used in designing and manufacturing parts may include receiving data from at least three data sources. The data sources may include a sourcing, manufacturing, and design data source. The data source data may be standardized to obtain a collection of data including a dataset of materials for consideration in recommending one or more materials for use in one or more parts. The method may also include receiving optimization metrics and constraints for the dataset of materials. Optimization values for each material based on the dataset of materials and the one or more optimization metrics may be determined. An optimization algorithm on each material may be performed based at least on the optimization values and the constraints to obtain one or more recommended materials from the dataset of materials for use in a design of one or more parts.

Abstract: Various embodiments may include determining a material utilization for one or more assemblies having a plurality of parts. Offal data for one or more parts comprising one or more part assemblies and a blank material utilization status for each of the one or more part assemblies may be received. The blank material utilization status for the one or more part assemblies may be based on a blank material utilization status for each of the one or more parts. The offal data may be standardized to obtain standardized offal data. One or more offal utilization assignments for the part assemblies having a plurality of parts may be determined based on the standardized offal data and the blank material utilization status for the part assemblies. The offal utilization assignments may then be transmitted for assignment to the one or more part assemblies.

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 for simulating a hydroforming process includes modeling a virtual hydroforming die and a virtual tubular workpiece. The virtual workpiece is placed within the die after the die has been expanded. The die is then contracted to a finished size while the workpiece is deformed into a non-circular cross section in contact with the virtual die. The workpiece is subsequently pressurized to simulate production of a finished part.

Abstract: A method for determining compensated addendum and binder surfaces as part of a springback compensated stamping die for producing a stamped part includes modeling of the existing addendum surface and binder surface of the stamping die. The addendum and binder surfaces are modified according to a number of compensatory surface displacements and in-plane rotations required for springback compensation of the finished stamped part. Following this modification, the stamped part may be separated from the addendum and binder without a loss of dimensional accuracy.

Abstract: A method for modifying a stamping die to compensate for springback includes the steps of stamping a first part using a base, or pre-existing die set, and creating a surrogate die having the shape of the first stamped part. These steps are followed by simulated stamping of a blank with the surrogate die, where the blank is shaped according to the desired finished part. Then, the base die is modified by mapping the forming stresses, from the stamped blank, to an indicator blank, which is allowed to relax and then is employed as a template for modification of the base die. Following this, the accuracy of the newly modified base die is determined by stamping a second part in the modified base die and by comparing a number of dimensions of the second part with a number of corresponding dimensions of the desired finished part.

Abstract: A method of developing a stamping die for a workpiece is provided, which includes the steps of stamping a workpiece in a current die. A measurement is made of the stamped workpiece to determine its profile. The profile is compared with the design intent workpiece to determine dimensional variance. If the variance is within predetermined limits, the development is complete. If the variance is beyond limits, a conceptual determination is made of the residual forces in the current die stamped workpiece when the current die stamped workpiece is restamped by a design intent die. This conceptual determination is carried out on a computer. From the determination of residual forces, a new current die is developed. The new current die then stamps the workpiece. The steps are repeated until the stamped workpiece profile is within predetermined limits.