Method and die set for forming a surface in a metal panel

Patent metadata

Field	Value
Publication number	US-10406587-B2
Application number	US-201615087380-A
Country	US
Kind code	B2
Filing date	Mar 31, 2016
Priority date	Mar 31, 2016
Publication date	Sep 10, 2019
Grant date	Sep 10, 2019

Abstract

A method of forming a surface in a panel includes positioning a panel blank between a stationary die and a moveable die of a die set, and moving the moveable die toward the stationary die to deform the panel blank therebetween. Positive stresses in the panel blank are maintained in the region of the panel blank that will form the surface by forming a bead along a length of the surface to be formed in the panel blank, as the moveable die moves toward the stationary die. The moveable die continues to move toward the stationary die, while maintaining positive stresses in the panel blank in the region of the panel blank that will form the surface, to further deform the panel blank into a formed shape that includes the surface.

First claim

The invention claimed is:

1. A method of forming a surface in a panel blank, the method comprising:
providing a die set having a stationary die and a moveable die that cooperate to define a formed shape therebetween, wherein one of the stationary die and the moveable die includes a male bead forming portion, and the other of the stationary die and the moveable die includes a female bead forming portion, wherein the formed shape defines the surface extending along a path, and a bead formed between the male bead forming portion and the female bead forming portion that extends parallel with the path of the surface;
wherein the bead is disposed between the surface and an edge of the panel blank;
positioning the panel blank between the stationary die and the moveable die;
moving the moveable die toward the stationary die to deform the panel blank therebetween, wherein the male bead forming portion and the female bead forming portion engage and deform the panel blank therebetween to form the bead during initial movement of the moveable die toward the stationary die to induce tensile forces in both a first direction parallel to the path of the surface and a second direction transverse to the path of the surface;
continuing to move the moveable die toward the stationary die to further deform the panel blank therebetween, while the bead is being formed between the male bead forming portion and the female bead forming portion, and while the panel blank includes tensile forces in both the first direction and the second direction relative to the path of the surface, to define the formed shape having the surface; and
removing an addendum of the panel blank adjacent the surface, after the panel blank is deformed into the formed shape;
wherein the bead is disposed within the addendum of the panel blank.

2. The method set forth in claim 1 further comprising clamping the panel blank to the stationary die.

3. The method set forth in claim 2 wherein clamping the panel blank to the stationary die is further defined as clamping the panel blank to the stationary die with a clamp, whereby the clamp engages the panel blank adjacent a portion of the panel blank that defines the surface, such that the portion of the panel blank that defines the surface is disposed between the clamp and an edge of the panel blank.

4. The method set forth in claim 3 wherein the bead of the formed shape is disposed between the surface and the edge of the panel blank, with the surface of the panel blank disposed between the bead and the clamp when positioned between the stationary die and the moveable die.

5. The method set forth in claim 1 wherein the male bead forming portion and the female bead forming portion each define a cross sectional shape perpendicular to the path of the surface that is operable to induce tensile forces in the panel blank in both the first direction parallel to the path of the surface and the second direction transverse to the path of the surface.

6. The method set forth in claim 5 wherein the cross sectional shape of the male bead forming portion and the female bead forming portion is dependent upon the formed shape.

7. The method set forth in claim 1 wherein the panel blank is a body side panel of a vehicle.

8. The method set forth in claim 7 wherein the surface is a roof surface for brazing attachment to a roof panel of the vehicle.

9. The method set forth in claim 1 wherein the path of the surface is a non-linear, three dimensional path.

10. The method set forth in claim 1 further comprising pre-forming a metal panel to define an intermediate shape forming the panel blank, prior to positioning the panel blank between the stationary die and the moveable die.

11. The method set forth in claim 1 wherein the surface of the formed shape of the panel blank includes a Class A finish surface.

12. The method set forth in claim 1 wherein the surface of the formed shape of the panel blank is smooth such that the surface includes no undulations extending above or below the surface a distance greater than plus or minus 0.25 mm per 250 mm.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Beauchamp Brian J
• Hunault Benjamin P
• Peck John G

Classifications

• B21D53/88

  other parts for vehicles, e.g. cowlings, mudguards · CPC title

• B21D24/04

  Blank holders; Mounting means therefor · CPC title

• B21D22/26

  for making peculiarly, e.g. irregularly, shaped articles · CPC title

• B21D22/22 Primary

  with devices for holding the edge of the blanks (B21D22/24 - B21D22/30 take precedence; shaping over a die without external former B21D11/02) · CPC title

• B21D19/08 Primary

  by single or successive action of pressing tools, e.g. vice jaws · CPC title