Abstract: A system includes a frame configured to hold a workpiece and first and second tool positioning assemblies configured to be opposed to each other on opposite sides of the workpiece. The first and second tool positioning assemblies each include a toolholder configured to secure a tool to the tool positioning assembly, a first axis assembly, a second axis assembly, and a third axis assembly. The first, second, and third axis assemblies are each configured to articulate the toolholder along a respective axis. Each axis assembly includes first and second guides extending generally parallel to the corresponding axis and disposed on opposing sides of the toolholder with respect to the corresponding axis. Each axis assembly includes first and second carriages articulable along the first and second guides of the axis assembly, respectively, in the direction of the corresponding axis.

Abstract: In a method for producing a structural part from an iron-manganese-stell sheet (1), a sheet-metal workpiece (2) is cold-formed in a forming die (3). The formed sheet-metal workpiece is heated to a temperature between 500° C. and 700° C. (4) and calibrated in a calibrating die (5).

Abstract: A forging press device for valve including an upsetter in which a plurality of primary forming stages are provided, a forging press main body adjacent to the upsetter, that secondarily forms a primary formed workpiece, and a workpiece conveyance/carry-in device which grips and conveys the workpiece, to carry it into the forging press main body, the device in which the workpiece conveyance/carry-in device is composed of a high speed multi jointed robot capable of circling around a vertical shaft, which has an arm (a chuck) gripping the workpiece. In accordance with the invention, it is possible to provide a forging press device for valve in which the number of deliveries of workpiece from the upsetter to the forging press main body is decreased, which speeds up a valve forging line, and improves the production efficiency.

Abstract: A stretch-forming apparatus includes a main frame which carries a die enclosure between jaw assemblies. The die enclosure includes radiant heaters for supplying heat to a workpiece being stretch-formed against the die.

Abstract: A system and method for shaping a net or near-net titanium part, the method comprising machining a piece of titanium into a titanium part having non-uniform thickness, heating the titanium part to a target temperature within a target temperature range between an auto-relief temperature of the titanium part and a minimum temperature required for super plastic forming of the titanium part, and lowering a die into the titanium part with sufficient force to shape the titanium part. The system for shaping the titanium part may comprise a multiple-axis machine, a die, electrical clamps, sensors, and a control system for adjusting heating temperatures based on information received from the sensors regarding the titanium part.

Abstract: An apparatus and method of uniformly heating, rheologically softening, and thermoplastically farming metallic glasses rapidly into a net shape using a rapid capacitor discharge forming (RCDF) tool are provided. The RCDF method utilizes the discharge of electrical energy stored in a capacitor to uniformly and rapidly heat a sample or charge of metallic glass alloy to a predetermined “process temperature” between the glass transition temperature of the amorphous material and the equilibrium melting point of the alloy in a time scale of several milliseconds or less. Once the sample is uniformly heated such that the entire sample block has a sufficiently low process viscosity it may be shaped into high quality amorphous bulk articles via any number of techniques including, for example, injection molding, dynamic forging, stamp forging, and blow molding in a time frame of less than 1 second.

Abstract: A method and apparatus are disclosed for making a hydro-formed part by first hydro-forming a tubular blank to form an initially formed part. The initially formed part is clamped in a calibration tool with clamps. The initially formed part is connected to a source of electric current and electric current is pulsed through the initially formed part to reduce internal stresses in the initially formed part and reduce spring-back to form the initially formed part to a target shape.

Abstract: In a method of making a shaped metal part for a motor vehicle component, a blank is made from a steel alloy containing, in weight percent: carbon (C) 0.18% to 0.3%, silicon (Si) 0.1% to 0.7%, manganese (Mn) 1.0% to 2.5%, phosphorus (P) maximal 0.025%, chromium (Cr) 0.1 to 0.8%, molybdenum (Mo) 0.1 to 0.5%, sulfur (S) maximal 0.01%, titanium (Ti) 0.02% to 0.05%, boron (B) 0.002% to 0.005%, aluminum (Al) 0.01% to 0.06%, balance iron and impurities resulting from smelting, The blank is heated to a temperature between 900° C. and 950° C., and formed in a press tool into a formed part which is quenched and tempered while still being in the press tool. At least one region of the formed part is then annealed to become soft by a heating operation within a time interval of less than 30 seconds to thereby provide the region with higher ductility.

Abstract: Method for bending tubular articles with a relative ratio of the bending radius (R) and the outer diameter (D) of the finished pipe which is less than 3, comprising the following steps: forging an article made of material with a predefined composition depending on the final use and with a predefined length (L) in the longitudinal direction and an outer diameter (D); providing a die having an asymmetrical bottom die half with seat for the pipe; and a top die half with punch asymmetrically arranged in the longitudinal direction (X-X) with respect to the vertical center axis of the die; heating the article in an oven to the required temperature for forging depending on the specific composition of the material; positioning the article inside the bottom die half in the longitudinal direction; closing of the two die halves so as to start bending of the article; opening the die; and extracting the bent article.

Abstract: A stretch-forming apparatus includes a main frame which carries a die enclosure between jaw assemblies. An insulated die is mounted in the enclosure. A method of forming a component includes placing a workpiece in the enclosure, heating the workpiece to a working temperature using electrical resistance heating, and then stretching the workpiece against the die. The method is particularly useful for titanium workpieces.

Abstract: A method for forming a sheet metal component using an electric current passing through the component is provided. The method can include providing a single point incremental forming, the machine operable to perform a plurality of single point incremental deformations on the sheet metal component and also apply an electric direct current to the sheet a metal component during at least part of the forming. The direct current can be applied before or after the forming has started and/or be terminated before or after the forming has stopped and can reduce the magnitude of force required to produce a given amount of deformation, increase the amount of deformation exhibited before failure and/or reduce any springback typically exhibited by the sheet metal component.

Abstract: A system and method for shaping a net or near-net titanium part, the method comprising machining a piece of titanium into a titanium part having non-uniform thickness, heating the titanium part to a target temperature within a target temperature range between an auto-relief temperature of the titanium part and a minimum temperature required for super plastic forming of the titanium part, and lowering a die into the titanium part with sufficient force to shape the titanium part. The system for shaping the titanium part may comprise a multiple-axis machine, a die, electrical clamps, sensors, and a control system for adjusting heating temperatures based on information received from the sensors regarding the titanium part.

Abstract: The subject matter of the present invention is a method of shaping a metallic hollow member in a shaping tool (1, 20, 50) at increased temperature and under internal pressure, said hollow member (5) protruding at one end at least from said shaping tool (1), the configuration of the tool mold and/or the shaping parameters acting onto said hollow member being selected in such a manner that said hollow member (5, 59) substantially keeps its original shape outside said tool (1, 20, 50), with said tool being heated in the region of the cavity and a tool, said tool being completely made from a homogeneous ceramic material with the component part being heated inductively, the cavity having a tribological additional coating in order to minimize friction of the component part against the wall and/or the affinity of the component part with the material of the cavity wall.

Abstract: A stretch-forming apparatus includes a main frame which carries a die enclosure between jaw assemblies. The die enclosure includes radiant heaters for supplying heat to a workpiece being stretch-formed against the die.

Abstract: A method of forming titanium structures, and more specifically, a method of superplastically continuous roll forming titanium structures are disclosed herein. In one embodiment, a method of forming a shape in an article comprising titanium, the method including, among other things, providing first and second rolling members, the first rolling members being conductive and the second rolling members being continuous roll shaping members; contacting the article with the first rolling members to transfer a current to the article to heat the article to a temperature suitable for superplastic forming; and with the article being in a superplastic state, contacting the article with the second rolling members to form the shape in the article.

Abstract: A stretch-forming apparatus includes a main frame which carries a die enclosure between jaw assemblies. An insulated die is mounted in the enclosure. A method of forming a component includes placing a workpiece in the enclosure, heating the workpiece to a working temperature using electrical resistance heating, and then stretching the workpiece against the die. The method is particularly useful for titanium workpieces.

Abstract: Magnesium and other metal alloy sheet materials are deformed at hot forming temperatures into vehicle body panels and other articles. Many such hot forming operations are improved in speed and product quality by predetermining a static recrystallization temperature of the sheet material. As the sheet material is being heated to its hot forming temperature, deformation is commenced below the static recrystallization temperature. As heating and deformation are continued, dynamic recrystallization of the workpiece occurs and deformation may proceed faster and to a greater extent.

Abstract: A process for manufacturing a surgical needle incorporates at least one pressing operation which, preferably, in conjunction with a trimming and/or etching process, ultimately forms the sharpened needle end. The grinding operation in the preferred process does not produce the primary sharpened edges of the needle, but, rather is incorporated, in one instance, to reduce excess needle material prior to the pressing operation. Consequently, the amount of flash material generated during pressing is substantially reduced. This feature desirably enhances the subsequent trimming and etching operations, and produces a needle which is extremely sharp, durable and exhibits an improved retention of sharpness over periods of prolonged use.

Abstract: The present invention relates to a heating and forming apparatus for sheet material and method for rapid heating and shaping of sheet material. The apparatus comprises a first and second respectively movable forming dies, with the first forming die having a forming surface and defining a cavity with the second forming die. The apparatus is adaptable to receive a sheet material positionable within the cavity. A heating mechanism is placed within the cavity to heat the sheet material. The forming surface of the first forming die is not substantially heated. A pressurization mechanism is in communication with the cavity to move the sheet material into conformity with the forming surface of the first die. An improvement in the process of stretch forming a sheet material into a product by using quick plastic forming (QPF) or superplastic forming (SPF) is provided.

Abstract: A method is provided for forming a sheet metal blank or tubular blank in a metal forming tool, such as a sheet metal press or a media forming tool. The sheet metal press has an upper die and a lower die that are moved by a press to form the metal blank. The forming tool has a plurality of electrodes that are connected in an electrical circuit to a source of direct current. The electrodes provide pulses of the electric current to at least a portion of the blank. The method comprises loading the blank into the forming tool and closing the upper die and the lower die. The electrical circuit is completed between multiple electrodes through one or more portions of the blank. Electrical current is pulsed intermittently through the blank in a plurality of pulses.

Abstract: A method for forming a sheet metal component using an electric current passing through the component is provided. The method can include providing a single point incremental forming, the machine operable to perform a plurality of single point incremental deformations on the sheet metal component and also apply an electric direct current to the sheet a metal component during at least part of the forming. The direct current can be applied before or after the forming has started and/or be terminated before or after the forming has stopped and can reduce the magnitude of force required to produce a given amount of deformation, increase the amount of deformation exhibited before failure and/or reduce any springback typically exhibited by the sheet metal component.

Abstract: A process for forming a tubular member is provided which includes a pre-forming process for tube-expanding (bulge) forming and bending forming a tubular material using first and second molds and a final forming process for crush forming a preformed tube using a third mold so as to give its cross section a desired shape, the pre-forming step being carried out using the first and second molds heated at temperatures equal to or higher than the recrystallization temperature of the tubular material and the final forming step being carried out using the third mold heated at temperatures equal to or lower than the recrystallization temperature of the tubular material. The process enables a tubular material of aluminum alloy to be formed into a tubular member of high precision and high quality which has expanded portions as well as bent portions and whose cross section varies across its length.

Abstract: A method of forming a vehicle component, particularly an elongated impact beam, having an open section structure, in a manner to provide predetermined strategically strengthened portions, comprising the steps of cold forming unhardened steel into a workpiece having mounting surfaces, selectively fixturing the mounting surfaces, static induction heating the workpiece with lengthwise surface eddy currents on selected portions, followed by quenching of the fixtured heated workpiece to form strengthened portions, and unfixturing the resulting component. Also disclosed is apparatus to accomplish this, and the resulting novel vehicle component.

Abstract: A method is provided for forming a sheet metal blank or tubular blank in a metal forming tool, such as a sheet metal press or a media forming tool. The sheet metal press has an upper die and a lower die that are moved by a press to form the metal blank. The forming tool has a plurality of electrodes that are connected in an electrical circuit to a source of direct current. The electrodes provide pulses of the electric current to at least a portion of the blank. The method comprises loading the blank into the forming tool and closing the upper die and the lower die. The electrical circuit is completed between multiple electrodes through one or more portions of the blank. Electrical current is pulsed intermittently through the blank in a plurality of pulses.

Abstract: A technique for manufacturing a product involves receiving material, providing plastic deformation to the material to at least partially form the product, and applying electric current to the material while providing the plastic deformation to the material. The electric current is configured to reduce flow stresses within the material during plastic deformation. In some arrangements, the electric current is a series of high-density, short electric pulses which increases plasticity due to increasing the dislocation mobility of the deformed material. In some arrangements, the electric current provides an electric current density through the material of at least 1000 Amperes per square millimeter with each electric pulse lasting no longer than 0.01 seconds.

Abstract: A system and method for superplastic forming a workpiece. The system includes a superplastic forming cell formed of a plurality of individual stations or modules, each one performing a specific manufacturing step or process on the workpiece. Individual stations include a preheat station, a forming station, a cooling station, a cleaning station and a trimming station. These stations work in conjunction with one another to reduce superplastic forming cycle times and correspondingly increased production times when manufacturing a workpiece using a superplastic forming process.

Abstract: Apparatus for shaping metal sheets including a shaping tool having an forming space for receiving a metal sheet. At least one heating element is disposed in a recess of the shaping tool for heating at least a portion of the metal sheet, whereby an insulation layer is provided to insulate the heating element from neighboring walls of the shaping tool.

Abstract: The present invention is a bending machine for bending material such as steel to form cutting dies for products such as cloth, leather or the like. Coiled material is fed through a material washer, straightener and printer by a material feeder to a bending head. If required the material is forwarded through the bending head to a heating unit and retracted to the bending unit to aid in bending. A nicking tool is also provided ahead of the bending tool to nick the material. The nicks enable the cutting die to cut notches in the product being cut. A support surface at the output end of the machine supports the material as it is bent into the required form.

Abstract: A warm hydro-forming device comprises: an upper mold and a lower mold respectively mounted to an upper mold die and a lower mold die; a lifting die installed to the lower mold die through a guide unit, an upper portion of the lifting die being connected to the upper mold die through a lifting unit to cooperatively operate in an upward and downward direction with the upper mold die; a pair of hydraulic pressure cylinders for providing an axial compression force to the tube component and supplying a forming hydraulic fluid into the tube component; an ascending and descending unit for ascending or descending the upper mold die; and a heating unit associated with the lifting die such that the heating unit can move toward or away from the tube component. The heating unit heats the tube component and a forming hydraulic fluid through a high frequency induction heating.

Abstract: The present invention is a bending machine for bending material such as steel to form cutting dies for products such as cloth, leather or the like. Coiled material is fed through a material washer, straightener and printer by a material feeder to a bending head. If required the material is forwarded through the bending head to a heating unit and retracted to the bending unit to aid in bending. A nicking tool is also provided ahead of the bending tool to nick the material. The nicks enable the cutting die to cut notches in the product being cut. A support surface at the output end of the machine supports the material as it is bent into the required form.

Abstract: A robotic bending apparatus for bending archwires and other types of elongate, bendable medical devices into a desired configuration includes a first gripping tool and a moveable gripping tool. The first gripping tool can be either fixed with respect to a base or table for the robot or positioned at the end of robot am. The moveable gripping tool is mounted to the end of a moveable robot arm having a proximal portion also mounted to the base. The robot preferably comprises a six axis bending robot, in which the distal end of the moveable arm can move relative to the fixed gripping tool about three translational axes and three rotational axes. The gripping tools preferably incorporate force sensors which are used to determine overbends needed to get the desired final shape of the archwire. The robot may also include a resistive heating system in which current flows through the wire while the wire is held in a bent condition to heat the wire and thereby retain the bent shape of the wire.

Abstract: A method of thermomechanically forming an aluminide part of a workpiece resistively heats at least a portion of the aluminide part, plastically deforms the heated portion of the aluminide part to a predetermined shape by applying pressure to the aluminide part positioned in a shaping member, and cools the aluminide part while applying pressure to maintain the aluminide part in the predetermined shape. The shaping member is movably mounted on a support base and a source of electricity provides an electrical current passing through the aluminide part for resistive heating of the part. The aluminide part can be a heater blade array for an electrically heated cigarette smoking system.

Abstract: A robotic bending apparatus for bending archwires and other types of elongate, bendable medical devices into a desired configuration includes a first gripping tool and a moveable gripping tool. The first gripping tool can be either fixed with respect to a base or table for the robot or positioned at the end of robot am. The moveable gripping tool is mounted to the end of a moveable robot arm having a proximal portion also mounted to the base. The robot preferably comprises a six axis bending robot, in which the distal end of the moveable arm can move relative to the fixed gripping tool about three translational axes and three rotational axes. The gripping tools preferably incorporate force sensors which are used to determine overbends needed to get the desired final shape of the archwire. The robot may also include a resistive heating system in which current flows through the wire while the wire is held in a bent condition to heat the wire and thereby retain the bent shape of the wire.

Abstract: A robotic bending apparatus for bending archwires and other types of elongate, bendable medical devices into a desired configuration includes a first gripping tool and a moveable gripping tool. The first gripping tool can be either fixed with respect to a base or table for the robot or positioned at the end of robot am. The moveable gripping tool is mounted to the end of a moveable robot arm having a proximal portion also mounted to the base. The robot preferably comprises a six axis bending robot, in which the distal end of the moveable arm can move relative to the fixed gripping tool about three translational axes and three rotational axes. The gripping tools preferably incorporate force sensors which are used to determine overbends needed to get the desired final shape of the archwire. The robot may also include a resistive heating system in which current flows through the wire while the wire is held in a bent condition to heat the wire and thereby retain the bent shape of the wire.

Abstract: A method of forming an elongated tubular blank into a tubular structural component having a predetermined outer configuration, the method comprising: providing a shape imparting shell formed from a low permeability, rigid material which includes an inner surface defining the predetermined shape, plugging the open ends of the tubular blank, placing the plugged blank into the shell, and forming the tubular blank into the tubular component by inductively heating axial portions of the blank by axially spaced conductors adjacent the shell while or before forcing gas at a high pressure into the plugged blank until the blank conforms to at least a portion of the inner surface of the shell to form the structural component.

Abstract: A robotic bending apparatus for bending archwires and other types of elongate, bendable medical devices into a desired configuration includes a first gripping tool and a moveable gripping tool. The first gripping tool can be either fixed with respect to a base or table for the robot or positioned at the end of robot arm. The moveable gripping tool is mounted to the end of a moveable robot arm having a proximal portion also mounted to the base. The robot preferably comprises a six axis bending robot, in which the distal end of the moveable arm can move relative to the fixed gripping tool about three translational axes and three rotational axes. The gripping tools preferably incorporate force sensors which are used to determine overbends needed to get the desired final shape of the archwire. The robot may also include a resistive heating system in which current flows through the wire while the wire is held in a bent condition to heat the wire and thereby retain the bent shape of the wire.

Abstract: A process and relevant tools for hot forming of high strength metal workpieces by means of applicating high density current to the workpiece directly and generating heat inside it by using its own electrical resistance in order to obtain desired temperature and formability at the desired moment of the forming process without requiring any external heat source or previous heating process. Temperature of the blank is measured by measuring its electrical resistance and by using linear correlation between temperature and resistance. This heating process can be applicated in several metal forming types such as high strength sheet stamping (FIG. 2, FIG. 3), bending (FIG. 3), blow forming (FIG. 4, FIG. 5) in accordance with mechanical operations of the relevant processes. High temperature rates can easily be reached and kept at the desired moment of the forming process without being effected by rapid cooling phenomena resulted by too much heat loss area/mass and heat storage capasitance of thin sheets.

Abstract: A method of forming an elongated tubular blank into a tubular structural component having a predetermined outer configuration, the method comprising: providing a shape imparting shell formed from a low permeability, rigid material which includes an inner surface defining the predetermined shape, plugging the open ends of the tubular blank, placing the plugged blank into the shell, and forming the tubular blank into the tubular component by inductively heating axial portions of the blank by axially spaced conductors adjacent the shell while or before forcing gas at a high pressure into the plugged blank until the blank conforms to at least a portion of the inner surface of the shell to form the structural component.

Abstract: A tubular axle having a spindle and a bearing shoulder is formed directly into heat-treated tubing. The method generally includes a heating operation, and a two stage forming operation. The first operation is to induction heat a steel tubular axle blank to a temperature less than 1500 degrees Fahrenheit. The next operation includes forcing a preform die assembly onto the tubular blank to reduce a length of the blank to a second diameter while forming an intermediate section having a first and second ramped section. The final operation includes forcing an upset die assembly onto the end of the blank to form a gathered material section formed intermediate the first ramped section and the second ramped section. The second diameter provides a pre-machined diameter for the final axle spindle and the gathered material section provides a pre-machined area for the final integral bearing shoulder.