A method for manufacturing a ring includes clamping a first region of a metal sheet against a mandrel, and, while the first region of the metal sheet is clamped against the mandrel, bending the metal sheet around the mandrel to join opposite end faces of the metal sheet and form the ring shaped to the mandrel. A system for manufacturing a ring from a metal sheet includes (a) a mandrel having a ring-shaped surface, (b) a clamp facing the ring-shaped surface and configured to clamp a first region of a metal sheet to the mandrel, and (c) a plurality of dies configured to bend the metal sheet around the mandrel, while the clamp clamps the first region to the mandrel, to join opposite end faces of the metal sheet and form a ring shaped to the ring-shaped surface.

Flanges formed on sheet metal parts to increase the part stiffness or create mating surface for further assembly are created in an incremental sheet forming process using forming tool and supporting tool that move along a specified tool path so as to gradually deform a peripherally-clamped sheet metal work piece into the desired geometry. With two universal tools moving along the designed toolpath on the both sides of the part, the process is very flexible. Process time is can also be reduced by utilizing an accumulative double-sided incremental hole-flanging strategy, in which the flange is formed in only one step.

An aerodynamic component of a gas turbine engine is provided and is fittable to a shell having a shell shape. The aerodynamic component includes a body having a component shape initially deviating from the shell shape prior to an assembly operation in which the aerodynamic component is to be fit to the shell. Deviation of the component shape from the shell shape aids in an establishment of a final desired shape of the aerodynamic component following the assembly operation.

A method for forming a blank of sheet material includes a step of forming a target shape from the blank. The target shape includes a plurality of component structures connected via a common addendum. Each one of the plurality of component structures has a component-shape and a component-boundary. The common addendum extends between the component-boundary of each one of plurality of component structures and connects the component-boundary of each one of the plurality of component structures with a perimeter of the blank. The method minimizes a projected area of the common addendum via adjustment of a position and/or orientation of each of the component structures, thereby reducing a total amount of sheet material required to form the component structures.

A process for forming a sheet metal component. The process includes rigidly clamping a piece of sheet metal to a clamping fixture and plastically deforming the sheet metal to produce a shaped component during a first manufacturing step. The shaped component has a first amount of springback. During a second manufacturing step, a pair of electrodes applies one or more pulses of electrical current at one or more locations on the shaped component while the shaped component is still rigidly clamped to the clamping fixture during. The one or more pulses of electrical current applied to the shaped component provide an electrically-assisted manufactured (EAM) shaped component. The EAM shaped component has a second amount of springback that is less than the first amount of springback.

Processes and methods related to processing and hot working alloy ingots are disclosed. A metallic material layer is deposited onto at least a region of a surface of an alloy ingot before hot working the alloy ingot. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

Processes and methods related to processing and hot working alloy ingots are disclosed. A metallic material layer is deposited onto at least a region of a surface of an alloy ingot before hot working the alloy ingot. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

A stabilizer having a tubular shape is provided so as to extend in a widthwise direction of a vehicle and coupled to a suspension arm at opposite end portions of the stabilizer. Each of the opposite end portions includes: a first large-diameter bar portion having an outside diameter greater than an outside diameter of an intermediate portion of the stabilizer; and a second large-diameter bar portion having an outside diameter greater than the outside diameter of the first large-diameter bar portion and having a wall thickness greater than a wall thickness of the intermediate portion.

A sheet metal system having incremental forming and direct metal deposition, includes a plate. A groove is created in the plate. A direct metal deposition tool is positioned within the groove. A material is deposited by the direct metal deposition tool onto a surface within the groove creating a rib.

An apparatus for forming a metal workpiece having a first surface is described herein. The apparatus includes a trough containing a liquid. The apparatus also includes a support for positioning the metal workpiece in an impact-receiving position. In the impact-receiving position, the first surface is submerged in the liquid. The apparatus includes a driven member for applying multiple impacts to the first surface of the metal workpiece while the metal workpiece is in the impact-receiving position.