阅读说明：本技术 由金属板形成凸缘以减少表面扭曲的成形装置和方法 (Forming apparatus and method for forming a flange from sheet metal to reduce surface distortion ) 是由 克里斯汀·吉尼罗 罗伯特·V·德根哈特 菲利普·郑 于 2019-07-03 设计创作，主要内容包括：本公开提供了“由金属板形成凸缘以减少表面扭曲的成形装置和方法”。一种形成车辆面板的方法包括在冲压工具之间使金属板工件变形以形成所述工件的主表面的拐角。第一边缘和第二边缘由所述主表面与第一凸缘或第二凸缘的接合部限定。所述第二凸缘具有相对于所述主表面弯曲到第一角度的第一区域和弯曲到一定角度的展开区域,所述展开区域随着所述第二凸缘接近所述拐角而从所述第一区域展开。所述工件在第二组冲压工具之间变形,所述第二组冲压工具使所述第一凸缘和所述展开区域变形,直到所述第一凸缘和所述第二凸缘弯曲大于90°。(The present disclosure provides a forming apparatus and method for forming a flange from sheet metal to reduce surface distortion. A method of forming a vehicle panel includes deforming a sheet metal workpiece between stamping tools to form corners of a major surface of the workpiece. The first edge and the second edge are defined by the junction of the major surface and the first flange or the second flange. The second flange has a first region that is bent to a first angle relative to the major surface and a flared region that is bent to an angle, the flared region flaring from the first region as the second flange approaches the corner. The workpiece is deformed between a second set of press tools that deform the first flange and the flared region until the first flange and the second flange bend more than 90 °.)

1. A method of forming a vehicle body panel from a sheet metal workpiece having a major surface, comprising:

deforming the workpiece between a first set of stamping tools to form a first edge of the major surface and a second edge of the major surface, the first edge and the second edge converging to define a corner of the major surface, the first edge defined by a junction of the major surface and a first flange, the second edge defined by a junction of the major surface and a second flange, wherein deforming the workpiece to form the first edge and the second edge comprises deforming the workpiece such that the second flange has a first region that curves to a first angle relative to the major surface and a flared region that curves to an angle relative to the major surface, the flared region flaring from the first region as the second flange approaches the corner; and

deforming the workpiece between a second set of stamping tools that deform the flared regions of the first and second flanges until the first and second flanges are bent greater than 90 ° relative to the major surface.

2. The method of claim 1, wherein the flared region of the second flange flares from a first amount of curvature greater than 90 ° relative to the major surface to a second amount of curvature greater than 0 ° and less than 90 ° relative to the major surface.

3. The method of claim 1, wherein the major surface is a class a surface.

4. The method of claim 1, wherein deforming the workpiece between the first set of stamping tools comprises controlling an angle of the spread region by pressing the spread region between an upper steel and a lower steel.

5. The method of claim 1, wherein the first set of press tools comprises a first flange post, a first flange steel, and a second flange steel, and wherein deforming the workpiece between the first set of press tools comprises:

positioning the workpiece on the first flange post;

moving the first flange steel in a first direction relative to the first flange column; and

moving the second flange steel relative to the first flange column in a second direction, the second direction being transverse to the first direction.

6. The method of claim 5, wherein working surfaces of the first and second flange steels are spaced from the first flange column by a thickness of the workpiece when the first and second flange steels are in a closed position relative to the first flange column.

7. The method of claim 5, wherein the first flange steel contacts the first flange when the first flange steel is in the closed position, wherein the second flange steel contacts the first region and the expanded region when the second flange steel is in the closed position.

8. The method of claim 7, wherein the first flange steel contacts a portion of the deployment area when the first flange steel is in the closed position.

9. The method of claim 7, wherein the second set of stamping tools includes a second flange post and a third flange steel movable in a third direction relative to the second flange post between an open position and a closed position, wherein the third flange steel contacts the expanded areas of the first and second flanges when the third flange steel is in the closed position.

10. A set of press tools for forming a vehicle body panel from a sheet metal workpiece having a major surface, a first flange along a first edge of the major surface, and a second flange along a second edge of the major surface, the first and second edges converging to form a corner of the major surface, the press tools comprising:

a first anvil;

a first pad configured to hold the workpiece against the first anvil;

a first flange steel movable between an open position and a closed position relative to the first anvil and the first pad, wherein the first flange steel is configured to contact the first flange to bend the first flange along the first edge when the first flange steel is moved from the open position to the closed position;

a second flange steel movable between an open position and a closed position relative to the first anvil and the pad, wherein the second flange steel is configured to contact a first region of the second flange to bend the first region along the second edge when the second flange steel is moved from the open position to the closed position;

wherein the second flange steel includes a first flared surface configured to contact a second region of the second flange when the second flange steel is moved from the open position to the closed position to bend the second region along the second edge by an amount that flares away from the first region as the second region approaches the corner;

wherein the first anvil includes a second flared surface configured to oppose the first flared surface, the first and second flared surfaces having angles flared relative to the major surface proximate the corner.

11. The press tool of claim 10, further comprising:

a second anvil;

a second pad configured to hold the workpiece against the second anvil after the workpiece has been deformed by the first and second flanged steels;

a third flange steel movable between an open position and a closed position relative to the second anvil and the second pad, wherein the third flange steel is configured to contact the first flange and the second region to bend the first flange and the second region to an angle greater than 90 ° relative to the major surface when the third flange steel is moved from the open position to the closed position.

12. The press tool of claim 10, wherein the major surface is a class a surface.

13. The press tool of claim 10, wherein working surfaces of the first and second flange steels are spaced from the first flange column by a thickness of the workpiece when the first and second flange steels are in the closed position.

14. The pressing tool of claim 10, wherein the first and second development surfaces develop from a first amount of curvature greater than 90 ° relative to the major surface to a second amount of curvature greater than 0 ° and less than 90 ° relative to the major surface.

Technical Field

The present disclosure relates to a flange forming apparatus and method of forming a flange on a sheet metal part to reduce surface distortion.

Background

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

The exterior body panels are typically required to have complex curvatures for class a surface treatments. Surfaces designated as class a surfaces require high tolerances because these surfaces are typically intended to be visible exterior surfaces in an assembled vehicle. Vehicle body panels are typically formed from sheet metal material by a stamping or pressing operation that deforms the metal into a desired shape. In order to create a smooth edge where the class a surface meets another part (e.g., the fender meets the headlamp or hood), the edge of the metal plate is typically bent to form an edge and a flange, which is the metal portion that is bent behind the class a surface. To achieve the desired functionality and aesthetics, the flange is typically bent at an angle greater than 90 ° relative to the class a surface such that the flange is bent back generally on the inside of the component.

Bending the flanges to this extent can be particularly difficult when the two flanges meet at the corners of a class a surface. Bending the flange near the corner using typical bending or stamping techniques can result in inconsistent bending and distortion of the class a surface geometry. These distortions may require post-operative finishing work (e.g., grinding, additional forming, etc.) to return the class a surface geometry to the desired shape and tolerances. These finishing operations add significant time, cost, and scrap rates to the manufacture of the parts.

The present disclosure addresses these and other limitations of conventional forming methods for sheet metal features such as flanges.

Disclosure of Invention

In one form, a method of forming a vehicle body panel from a sheet metal workpiece having a major surface includes deforming the workpiece between a first set of stamping tools to form a first edge of the major surface and a second edge of the major surface that converge to define a corner of the major surface. The first edge is defined by the junction of the major surface and the first flange. The second edge is defined by the junction of the major surface and the second flange. Deforming the workpiece to form the first edge and the second edge includes deforming the workpiece such that the second flange has a first region that is bent to a first angle relative to the major surface and a flared region that is bent to an angle relative to the major surface, the flared region being flared from the first region as the second flange approaches the corner. The method also includes deforming the workpiece between the second set of stamping tools. A second set of tools deforms the flared regions of the first and second flanges until the first and second flanges are bent greater than 90 ° relative to the major surface.

According to another form, the developed region of the second flange develops from a first amount of curvature greater than 90 ° with respect to the main surface to a second amount of curvature greater than 0 ° and less than 90 ° with respect to the main surface.

In another form the major surface is a class a surface.

In yet another variation, the step of deforming the workpiece between the first set of press tools includes controlling an angle of the flared region by pressing the flared region between the upper and lower steels.

In yet another form the first set of press tools includes a first flanged post, a first flanged steel, and a second flanged steel. The step of deforming the workpiece between the first set of press tools includes positioning the workpiece on a first flange post, moving a first flange steel in a first direction relative to the first flange post, and moving a second flange steel in a second direction relative to the first flange post. The second direction is transverse to the first direction.

In yet another variation, the working surfaces of the first and second flange steels are spaced apart from the first flange column by the thickness of the workpiece when the first and second flange steels are in a closed position relative to the first flange column.

According to another form, the first flange steel contacts the first flange when the first flange steel is in the closed position. The second flange steel contacts the first region and the expanded region when the second flange steel is in the closed position.

In yet another form the first flange steel contacts a portion of the deployment area when the first flange steel is in the closed position.

In yet another form the second set of press tools includes a second flange column and a third flange steel movable in a third direction relative to the second flange column between an open position and a closed position. The third flange steel contacts the expanded areas of the first flange and the second flange when the third flange steel is in the closed position.

In another form, a method of forming a vehicle panel from a sheet metal workpiece having a surface includes forming a first flange and forming a second flange that transitions from a first region that is bent greater than 90 ° relative to the surface to a second region that is bent less than 90 ° relative to the surface. The second region and the first flange converge at a corner of the surface. The method further comprises subsequently bending the second region by more than 90 ° relative to the surface.

According to another form, the step of forming the second flange includes pressing the workpiece between a first set of press tools. A first set of stamping tools contact the front and back sides of the second flange along the first and second regions to provide controlled bending along the first and second regions.

In yet another form the step of forming the first flange includes bending the first flange to a first angle relative to the surface. The step of bending the second region by more than 90 ° comprises pressing the workpiece between a second set of press tools. The second set of stamping tools includes a flanged steel that deforms the second region to bend greater than 90 ° relative to the surface and deforms the first flange to a second angle that is greater than the first angle.

In yet another variation, the step of forming the first flange includes pressing the workpiece between a first set of press tools. The first set of stamping tools includes a first flange steel that contacts and forms at least a portion of the first flange and the second region.

According to another form, the surface is a class a surface.

In yet another form the steps of forming the first flange and forming the second flange include: positioning a workpiece on the flange post; moving the first flange steel in a first direction relative to the flange post to press the workpiece between the first flange steel and the flange post to form a first flange; and moving the second flange steel in a second direction relative to the flange post to press the workpiece between the second flange steel and the flange post to form a majority of the second flange.

In yet another form, the working surfaces of the first and second flange steels are spaced from the flange column by the thickness of the workpiece when the first and second flange steels are in a closed position relative to the flange column.

According to another form the first flange steel contacts the first flange when the first flange steel is in the closed position and the second flange steel contacts the first region and the second region when the second flange steel is in the closed position.

In yet another form the first flange steel contacts the second region when the first flange steel is in the closed position.

In another form, a set of stamping tools for forming a vehicle body panel from a sheet metal workpiece is provided. The body panel has a class A surface, a first flange along a first edge of the class A surface, and a second flange along a second edge of the class A surface. The first edge and the second edge converge to form a corner of the class a surface. The press tool includes a first anvil, a first pad, a first flanged steel, and a second flanged steel. The first pad is configured to hold the workpiece against the first anvil. The first flanged steel is movable between an open position and a closed position relative to the first anvil and the first pad. The first flange steel is configured to contact the first flange to bend the first flange along the first edge when the first flange steel is moved from the open position to the closed position. The second flanged steel is movable between an open position and a closed position relative to the first anvil and the pad. The second flange steel is configured to contact the first region of the second flange to bend the first region along the second edge when the second flange steel is moved from the open position to the closed position. The second flange steel includes a first flared surface configured to contact a second region of the second flange when the second flange steel is moved from the open position to the closed position to bend the second region along the second edge by an amount that flares away from the first region when the second region approaches the corner. The first anvil includes a second deployment surface configured to oppose the first deployment surface. The first flared surface and the second flared surface have angles flared relative to the class a surface proximate the corner.

According to another form, the press tool further includes a second anvil, a second pad, and a third flanged steel. The second pad is configured to hold the workpiece against the second anvil after the workpiece has been deformed by the first and second flanged steels. The third flanged steel is movable between an open position and a closed position relative to the second anvil and the second pad. The third flange steel is configured to contact the first flange and the second region to bend the first flange and the second region to an angle greater than 90 ° relative to the class a surface when the third flange steel is moved from the open position to the closed position.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

In order that the disclosure may be well understood, various forms thereof will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a first set of press tools showing a main pad, a first flange steel and a second flange steel in an open position relative to an anvil and a sheet metal workpiece according to the teachings of the present disclosure;

FIG. 2 is a perspective view of a first side of the anvil of FIG. 1;

FIG. 3 is a perspective view of a second side of the anvil of FIG. 1;

FIG. 4 is a perspective view of the tool set of FIG. 1 showing the main pad in a closed position with the first and second flange steels in an open position;

FIG. 5 is a perspective view of the tool set of FIG. 1 showing the first flange steel in an open position and the second flange steel in a closed position, with the main pad omitted from view for purposes of illustration;

FIG. 6 is a perspective view of the tool set of FIG. 1 showing the main pad and first flange steel in a closed position and the second flange steel in an open position;

FIG. 7 is a perspective view of the tool set of FIG. 1 showing the first and second flange steels in a closed position, with the main pad omitted from view for illustrative purposes;

FIG. 8 is a cross-sectional view of the tool set of FIG. 1 taken along line 8-8 shown in FIG. 7, showing the main pad, the first flange steel and the second flange steel in a closed position;

FIG. 9 is a cross-sectional view of the tool set of FIG. 1 taken along line 9-9 shown in FIG. 7, showing the main pad, the first flange steel and the second flange steel in a closed position;

FIG. 10 is a cross-sectional view of the tool set of FIG. 1 taken along line 10-10 shown in FIG. 7, showing the main pad, the first flange steel and the second flange steel in a closed position;

FIG. 11 is a cross-sectional view of the tool set of FIG. 1 taken along line 11-11 shown in FIG. 7, showing the main pad, the first flange steel and the second flange steel in a closed position;

FIG. 12 is a plan view of the outside of the workpiece of FIG. 1 after the workpiece of FIG. 1 has been pressed between the toolsets of FIG. 1;

FIG. 13 is a plan view of the inside of the workpiece of FIG. 12;

FIG. 14 is a perspective view of a second set of tools showing a third flange steel in an open position relative to a second anvil according to the teachings of the present disclosure;

FIG. 15 is a perspective view of the tool set of FIG. 14 showing the third flange steel in a closed position;

FIG. 16 is a cross-sectional view of the tool set of FIG. 14 taken along line 16-16 shown in FIG. 15, showing the second pad and the third flange steel in a closed position; and

fig. 17 is a plan view of the inside of the workpiece of fig. 12 after the workpiece has been pressed between the tool sets of fig. 14.

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

Detailed Description

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

Referring to fig. 1, a first set of press tools 10 for performing a first set of press operations on a sheet metal workpiece 14 is shown. The first set of press tools 10 includes a flanged post (i.e., first anvil 18), a first pad 22, a first flanged steel 26, and a second flanged steel 30. In the example provided, the first anvil 18 is substantially stationary, while the first pad 22, the first flanged steel 26, and the second flanged steel 30 are movable relative to the first anvil 18 and may be moved by a press (not shown, e.g., a hydraulic press). The first flanged steel 26 is generally movable relative to the first anvil 18 along a first axis or direction 38. First pad 22 and second flanged steel 30 are generally movable relative to first anvil 18 along a second axis or direction 34. First pad 22 and second flanged steel 30 may also move relative to each other along second direction 34. Second direction 34 is transverse to first direction 38. In fig. 1, first pad 22, first flanged steel 26, and second flanged steel 30 are shown in an open (i.e., retracted) position relative to first anvil 18 such that workpiece 14 may be inserted between first anvil 18 and first pad 22 or removed from between first anvil 18 and first pad 22. Referring additionally to fig. 4, first pad 22 is shown in a closed position relative to first anvil 18 with first flange steel 26 and second flange steel 30 in their respective open positions.

Returning to FIG. 1, and with additional reference to FIGS. 2 and 3, the first anvil 18 has a support surface 42, a first anvil edge 46, a second anvil edge 50, a first curved surface 54, and a second curved surface 58. The support surface 42 is configured to support an inner surface 62 (fig. 13) of the workpiece 14. The support surface 42 generally matches the shape of the inner surface 62 of the workpiece 14. The first anvil edge 46 is defined by the intersection of the support surface 42 and the first curved surface 54. The second anvil edge 50 is defined by the intersection of the support surface 42 and the second curved surface 58. The first anvil edge 46 and the second anvil edge 50 converge at a corner 66 of the first anvil 18.

The first curved surface 54 forms an acute angle with the support surface 42 along the first anvil edge 46. In the example provided, the acute angle between the first curved surface 54 and the support surface 42 is relatively consistent and continues up to the corner 66. The second curved surface 58 forms a varying angle with the support surface 42 along the second anvil edge 50 such that the second curved surface 58 forms an acute angle with the support surface 42 in a first region 70 away from the corner 66. As the second anvil edge 50 approaches the corner 66, the angle between the second curved surface 58 and the support surface 42 spreads out (i.e., becomes flatter). In other words, as the second anvil edge 50 approaches the corner 66, the second curved surface 58 becomes substantially more parallel to the support surface 42. In the example provided, the second curved surface 58 has a relatively uniform angle in the first region 70 and begins a controlled deployment at a second region 74 proximate the corner 66. In the example provided, the angle between the second curved surface 58 and the support surface 42 does not fully spread out to the extent of being flat with the support surface 42, but rather maintains a slight angle proximate the corner 66 to still define the second anvil edge 50.

When the workpiece 14 is supported on the first anvil 18, a first edge 78 of the workpiece 14 overhangs the first anvil edge 46 and a second edge 82 of the workpiece 14 overhangs the second anvil edge 50. The first and second edges 78, 82 of the workpiece 14 converge at a corner 86 of the workpiece 14, the corner 86 overhanging the corner 66 of the first anvil 18.

The first pad 22 has a clamping surface 90 opposite the support surface 42 and generally matching the shape of the major outer surface of the workpiece 14. In the example provided, the major outer surface of the workpiece is a class a surface and is designated by reference numeral 94. When the first pad 22 is in the closed position (fig. 4), the clamping surface 90 is configured to contact the class a surface 94 and hold the workpiece 14 against the support surface 42 with sufficient pressure to hold the workpiece 14 stationary relative to the first anvil 18.

As shown in fig. 4, first pad 22 may be in a closed position when first flange steel 26 and second flange steel 30 are in their open positions. From this position, first flange steel 26 and second flange steel 30 may be moved to their closed positions. In the example provided, first flange steel 26 and second flange steel 30 may be moved simultaneously to form their respective bends simultaneously. Referring additionally to fig. 5, first flange steel 26 is shown in an open position and second flange steel 30 is shown in a closed position. In fig. 5, first pad 22 is omitted from view to better illustrate second flanged steel 30. Referring additionally to fig. 6, first flange steel 26 is shown in a closed position, while second flange steel 30 is shown in an open position. Referring additionally to fig. 7, first flange steel 26 and second flange steel 30 are shown in their closed positions, and first pad 22 is omitted from the view for clarity of illustration. As shown in fig. 7, first flange steel 26 and second flange steel 30 are separated by gap 110 when in the closed position. In the example provided, the gap 110 is about 0.4 mm.

Referring to fig. 5-7, first flange steel 26 includes a working surface 114, the working surface 114 having a first region 118 and a second region 122, the first region 118 and the second region 122 converging at an inner corner 126 of the working surface 114. The first region 118 of the working surface 114 generally has a profile corresponding to the first anvil edge 46. The corner 126 of the working surface 114 has a profile corresponding to the corner 66 of the first anvil 18. A second region 122 of the working surface 114 has a profile corresponding to a portion of the second anvil edge 50.

First region 118 is opposite first curved surface 54 when first flanged steel 26 is in the closed position. In the example provided, when the first flange steel 26 is in the closed position, the first region 118 is spaced from the first bending surface 54 by the thickness of the workpiece 14 at the first edge 78 such that moving the first flange steel 26 to the closed position bends the first edge 78 of the workpiece 14 around the first anvil edge 46 to begin forming a first flange 130 (as shown in fig. 13). Second section 122 of first flange steel 26 is opposite second section 74 of second curved surface 58 when first flange steel 26 is in the closed position. In the example provided, when first flange steel 26 is in the closed position, second region 122 of first flange steel 26 maintains a spacing from second region 74 of second bending surface 58 that is the thickness of workpiece 14 at second edge 82, such that moving first flange steel 26 to the closed position bends second edge 82 of workpiece 14 around second anvil edge 50 to begin forming a portion of second flange 134 (shown in fig. 13).

Second flanged steel 30 includes a working surface 138, working surface 138 having a profile generally corresponding to second anvil edge 50. The working surface 138 has a profile that corresponds to a portion of the second anvil edge 50 from the second region 122 of the first flanged steel 26 in a direction away from the corner 66.

Working surface 138 opposes second curved surface 58 when second flange steel 30 is in the closed position. In the example provided, working surface 138 is spaced from second bending surface 58 by the thickness of workpiece 14 at second edge 82 when second flange steel 30 is in the closed position, such that moving second flange steel 30 to the closed position bends second edge 82 of workpiece 14 around second anvil edge 50 to form a portion of second flange 134. In the example provided, a portion of the working surface 138 opposes a portion of the second region 74 (i.e., a portion of the controlled deployment region), and the working surface 138 extends along the second anvil edge 50 until opposing the first region 70. In other words, the working surfaces 114, 138 cooperate to form adjacent portions of the deployed second region 74. In the example provided, working surface 138 of second flange steel 30 is opposite the fully expanded portion of second section 74, and the angle of working surface 114 and the corresponding portion of section 74 remains substantially constant up to corner 66. In an alternative configuration, not specifically shown, the deployment angle may continue into working surface 114 of first flanged steel 26.

With additional reference to fig. 8-11, cross-sectional views are provided to better illustrate the advancement and deployment of the second curved surface 58 and the working surfaces 114, 138. Fig. 8 shows a position corresponding to first region 70 where workpiece 14 is contacted by first anvil 18, first pad 22, first flanged steel 26, and second flanged steel 30. In this position, the second edge 82 of the workpiece 14 is bent greater than 90 ° around the second anvil edge 50. Fig. 9 shows a position closer to corner 66 than shown in fig. 8 and corresponding to expanded second region 74, where workpiece 14 is contacted by first anvil 18, first pad 22, first flanged steel 26, and second flanged steel 30. In this position, the second edge 82 of the workpiece 14 is bent about 90 ° around the second anvil edge 50. Fig. 10 shows a position closer to corner 66 than shown in fig. 9 and corresponding to expanded second region 74, where workpiece 14 is contacted by first anvil 18, first pad 22, first flanged steel 26, and second flanged steel 30. In this position, the second edge 82 of the workpiece 14 is bent less than 90 ° around the second anvil edge 50. Fig. 11 shows a position closer to corner 66 than shown in fig. 10 and corresponding to an expanded second region 74 where workpiece 14 is contacted by first anvil 18, first pad 22, and first flanged steel 26, but not by second flanged steel 30. At this location, the second edge 82 of the workpiece 14 is bent less than 90 ° around the second anvil edge 50, and in the example provided, approximately equal to the amount at the location shown in fig. 10. In the example provided, the first edge 78 of the workpiece 14 is bent greater than 90 ° around the first anvil edge 46 along the length of the first anvil edge 46 (e.g., in the position shown in fig. 8-11).

Referring additionally to fig. 12 and 13, workpiece 14 is shown after being bent by first second flanged steel 26 and second flanged steel 30. Fig. 12 shows the outside of the workpiece 14. As shown, as the first flange 130 approaches the corner 86 of the workpiece 14, the first flange 130 expands in a manner corresponding to the second region 74. Fig. 13 shows the inside of the workpiece 14 including the first flange 130 and the second flange 134.

With additional reference to fig. 14, after bending the workpiece with first and second flanged steels 26 and 30, workpiece 14 (i.e., in the state shown in fig. 12 and 13) is then disposed between a second set of press tools 210. The second set of press tools 210 includes a second flanged post (i.e., second anvil 214), a second pad 218 (shown in fig. 16), and a third flanged steel 222. The workpiece 14 is disposed on the second anvil 214. The second anvil 214 has a support surface 226, a first anvil edge 230, and a second anvil edge 234. The support surface 226 contacts and supports the inner surface 62 of the workpiece 14. The first and second anvil edges 46, 50 correspond to the first and second edges 78, 82 and converge at a corner 238, the corner 238 corresponding to and nesting within the corner 86 of the workpiece 14. The first anvil edge 230 is defined along a junction between the support surface 226 and the first curved surface 242 of the second anvil 214. The second anvil edge 234 is defined along a junction between the support surface 226 and a second curved surface 246 of the second anvil 214.

The first curved surface 242 forms an acute angle with the support surface 226 along the first anvil edge 230. In the example provided, the acute angle between first curved surface 242 and support surface 226 is sharper than the angle between support surface 42 (fig. 8-11) and first curved surface 54 (fig. 8-11), and is relatively consistent as it continues up to corner 238. The second curved surface 246 forms an acute angle with the support surface 226 along the second anvil edge 234. In the example provided, the acute angle between second curved surface 246 and support surface 226 is sharper and relatively consistent than the angle between support surface 42 (fig. 8-11) and flared second region 74 (fig. 8-11), and continues up to corner 238.

The second pad 218 (fig. 16) is movable relative to the second anvil 214 in the second direction 34 between an open position and a closed position (shown in fig. 16). In the closed position, the second pad 218 contacts the class a surface 94 of the workpiece 14 and holds the workpiece 14 against the second anvil 214.

Referring to fig. 14-16, third flanged steel 222 is movable relative to second anvil 214 and second pad 218 along a third axis or third direction 250. Third direction 250 is transverse to second direction 34 and first direction 38. Third flanged steel 222 is movable between an open position (shown in fig. 14) and a closed position (shown in fig. 15 and 16).

Third flange steel 222 has a continuous working surface 310, where working surface 310 has a first region 314 and a second region 318, where first region 314 and second region 318 converge at an interior corner 322. First region 314 is configured to mate with and oppose first curved surface 242. Second region 318 is configured to mate with and oppose second curved surface 246. Corner 322 of third flange steel 222 is configured to mate with corner 238 of second anvil 214 and wrap around the junction between first curved surface 242 and second curved surface 246.

In the example provided, when third flange steel 222 is in the closed position, first region 314 is spaced apart from first curved surface 242 by a distance equal to the thickness of first flange 130, and second region 318 is spaced apart from second curved surface 246 by a distance equal to second flange 134. Thus, moving third flanged steel 222 to the closed position bends first flange 130 further around first anvil edge 230 and also bends second flange 134 further around second anvil edge 234.

After bending the first and second flanges 130, 134 between the second anvil 214 and the third flange steel 222, the first and second flanges 130, 134 have been bent greater than 90 ° relative to the class a surface 94 along the length of the first and second edges 78, 82 (including at the corner 238). Because the workpiece 14 is bent around the second anvil 214 itself at the first and second flanges 130, 134, the second anvil 214 must be moved in a direction away from the corner 86 of the workpiece 14 in order to retrieve the workpiece 14. Fig. 17 shows the inside of the workpiece 14 after extraction. By bending the workpiece 14 using the tools and methods described herein, including the controlled expansion proximate the corner 66, the first flange 130 and the second flange 134 may be formed without distorting the class a surface 94 of the workpiece 14.

Although the steps of the method are described with reference to a particular example order of steps, the example order is not intended to be construed as the only possible order of steps.

Accordingly, the teachings of the present disclosure provide a stamping tool and a cost-effective method for forming a flange that consistently bends more than 90 ° to a corner of a workpiece while maintaining a class a surface proximate to the corner.

The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.

According to the present invention, a method of forming a vehicle body panel from a sheet metal workpiece having a major surface includes: deforming a workpiece between a first set of stamping tools to form a first edge of the major surface and a second edge of the major surface, the first edge and the second edge converging to define a corner of the major surface, the first edge defined by a junction of the major surface and a first flange, the second edge defined by a junction of the major surface and a second flange, wherein deforming the workpiece to form the first edge and the second edge comprises deforming the workpiece such that the second flange has a first region that curves to a first angle relative to the major surface and a flared region that curves to an angle relative to the major surface, the flared region flaring from the first region as the second flange approaches the corner; and deforming the workpiece between a second set of stamping tools that deform the flared regions of the first and second flanges until the first and second flanges are bent greater than 90 ° relative to the major surface.

According to one embodiment, the flared region of the second flange flares from a first amount of curvature greater than 90 ° with respect to the main surface to a second amount of curvature greater than 0 ° and less than 90 ° with respect to the main surface.

According to one embodiment, the main surface is a class a surface.

According to one embodiment, deforming the workpiece between the first set of press tools includes controlling an angle of a spread area between the upper steel and the lower steel by pressing the spread area.

According to one embodiment, the first set of press tools includes a first flange post, a first flange steel, and a second flange steel, wherein the step of deforming the workpiece between the first set of press tools includes: positioning a workpiece on a first flange post; moving the first flange steel in a first direction relative to the first flange column; and moving the second flanged steel relative to the first flanged column in a second direction, the second direction being transverse to the first direction.

According to one embodiment, the working surfaces of the first and second flange steels are spaced apart from the first flange column by the thickness of the workpiece when the first and second flange steels are in a closed position relative to the first flange column.

According to one embodiment, the first flange steel contacts the first flange when the first flange steel is in the closed position, wherein the second flange steel contacts the first area and the expanded area when the second flange steel is in the closed position.

According to one embodiment, the first flange steel contacts a portion of the deployment area when the first flange steel is in the closed position.

According to one embodiment, the second set of stamping tools includes a second flange column and a third flange steel movable in a third direction relative to the second flange column between an open position and a closed position, wherein the third flange steel contacts the expanded areas of the first and second flanges when the third flange steel is in the closed position.

According to the present invention, a method of forming a vehicle panel from a sheet metal workpiece having a surface includes forming a first flange; forming a second flange that transitions from a first region that is curved more than 90 ° relative to the surface to a second region that is curved less than 90 ° relative to the surface, the second region and the first flange converging at a corner of the surface; the second region is bent more than 90 ° relative to the surface.

According to one embodiment, the step of forming the second flange includes pressing the workpiece between a first set of stamping tools that contact the front and back sides of the second flange along the first and second regions to provide controlled bending along the first and second regions.

According to one embodiment, the step of forming the first flange comprises bending the first flange to a first angle relative to the surface, wherein the step of bending the second region by more than 90 ° comprises pressing the workpiece between a second set of press tools, wherein the second set of press tools comprises a flanged steel that deforms the second region to bend by more than 90 ° relative to the surface and deforms the first flange to a second angle that is larger than the first angle.

According to one embodiment, the step of forming the first flange includes pressing the workpiece between a first set of press tools, wherein the first set of press tools includes a first flange steel that contacts and forms at least a portion of the first flange and the second region.

According to one embodiment, the surface is a class a surface.

According to one embodiment, the steps of forming the first flange and forming the second flange include positioning a workpiece on a flange post; moving the first flange steel in a first direction relative to the flange post to press the workpiece between the first flange steel and the flange post to form a first flange; and moving the second flange steel in a second direction relative to the flange post to press the workpiece between the second flange steel and the flange post to form a majority of the second flange.

According to one embodiment, the working surfaces of the first and second flange steels are spaced from the flange column by the thickness of the workpiece when the first and second flange steels are in a closed position relative to the flange column.

According to one embodiment, the first flange steel contacts the first flange when the first flange steel is in the closed position, and the second flange steel contacts the first region and the second region when the second flange steel is in the closed position.

According to one embodiment, the first flange steel contacts the second region when the first flange steel is in the closed position.

According to the invention, a set of press tools for forming a vehicle body panel from a sheet metal workpiece having a class a surface, a first flange along a first edge of the class a surface and a second flange along a second edge of the class a surface, the first and second edges converging to form a corner of the class a surface, is provided with: a first anvil; a first pad configured to hold the workpiece against the first anvil; a first flange steel movable between an open position and a closed position relative to the first anvil and the first pad, wherein the first flange steel is configured to contact the first flange to bend the first flange along the first edge when the first flange steel is moved from the open position to the closed position; a second flange steel movable between an open position and a closed position relative to the first anvil and the pad, wherein the second flange steel is configured to contact a first region of the second flange to bend the first region along the second edge when the second flange steel is moved from the open position to the closed position; wherein the second flange steel includes a first flared surface configured to contact a second region of the second flange when the second flange steel is moved from the open position to the closed position to bend the second region along the second edge by an amount that flares away from the first region as the second region approaches the corner; wherein the first anvil includes a second flared surface configured opposite the first flared surface, the first and second flared surfaces having angles flared relative to the class A surface proximate the corner.

According to one embodiment, the above invention is further characterized by: a second anvil; a second pad configured to hold the workpiece against the second anvil after the workpiece has been deformed by the first and second flanged steels; a third flanged steel movable between an open position and a closed position relative to the second anvil and the second pad, wherein the third flanged steel is configured to contact the first flange and the second region to bend the first flange and the second region to an angle greater than 90 ° relative to the class a surface when the third flanged steel is moved from the open position to the closed position.