A bumper beam is roll formed so that it gets a closed cross section with, along the length, constant cross section having at least two closed chambers (15, 16) separated by an essentially horizontal partition wall (14). Each chamber has a side (19), which is turned away from the vehicle, with at least one longitudinal concave portion (20, 21; 22, 23) extending along the entire length and one side (24), which is facing the vehicle, with at least one longitudinal convex portion (25, 26; 27, 28) extending along the entire length. After the roll forming, some portions (32) of the cross section are pressed together vertically or horizontally in order to adapt the deformation properties.

A bumper beam is roll formed so that it gets a closed cross section with, along the length, constant cross section having at least two closed chambers (15, 16) separated by an essentially horizontal partition wall (14). Each chamber has a side (19), which is turned away from the vehicle, with at least one longitudinal concave portion (20, 21; 22, 23) extending along the entire length and one side (24), which is facing the vehicle, with at least one longitudinal convex portion (25, 26; 27, 28) extending along the entire length. After the roll forming, some portions (32) of the cross section are pressed together vertically or horizontally in order to adapt the deformation properties.

A method for producing a metal sheet with raised lines uses a rolling mill including roll stands. In a preparing step, a grooved roll is prepared, the grooved roll including grooves. In a choosing step, a stand at least one stage before the last stand is chosen. In an incorporating step, the grooved roll is incorporated in as an upper roil of the chosen, specified stand. In a forming step, a workpiece is formed into a metal sheet with raised lines formed corresponding to the respective grooves. In the forming step, a maximum rolling reduction achieved by rolls of the specified stand is set to a provisional value that is lower than a required value. After the leading edge of the workpiece reaches the stand next to the specified stand, the maximum rolling reduction of the specified stand is changed to the required value.

A method for producing a metal sheet with raised lines uses a rolling mill including roll stands. In a preparing step, a grooved roll is prepared, the grooved roll including grooves. In a choosing step, a stand at least one stage before the last stand is chosen. In an incorporating step, the grooved roll is incorporated in as an upper roil of the chosen, specified stand. In a forming step, a workpiece is formed into a metal sheet with raised lines formed corresponding to the respective grooves. In the forming step, a maximum rolling reduction achieved by rolls of the specified stand is set to a provisional value that is lower than a required value. After the leading edge of the workpiece reaches the stand next to the specified stand, the maximum rolling reduction of the specified stand is changed to the required value.

One aspect of the invention concerns a metallic bar or post (15) comprising a longitudinal axis; a spine (16) extending along the longitudinal axis; and at least three interconnected arms (17-19), each of which extends along the spine (16) and generally radially from the spine (16), with a free end (20-22) of each said arm (17-19) being tapered in the direction of the free end (20-22) to the spine (16). Other aspects of the invention concern a roll stand and rolling mill for forming the bar or post (15).

One aspect of the invention concerns a metallic bar or post (15) comprising a longitudinal axis; a spine (16) extending along the longitudinal axis; and at least three interconnected arms (17-19), each of which extends along the spine (16) and generally radially from the spine (16), with a free end (20-22) of each said arm (17-19) being tapered in the direction of the free end (20-22) to the spine (16). Other aspects of the invention concern a roll stand and rolling mill for forming the bar or post (15).

Disclosed are a method and system to form a contoured structure using deep rolling. The method includes using deep rolling to introduce plastic deformation to one or more portions of a work piece to form a convex contour in the work piece. The work piece, and subsequently formed contoured structure, can be metal or composite. The disclosed deep rolling systems and methods form, for example contoured aircraft panels, while also providing fatigue strength improvement and low level of work hardening during the forming process rather than as a post-production surface treatment.

Disclosed are a method and system to form a contoured structure using deep rolling. The method includes using deep rolling to introduce plastic deformation to one or more portions of a work piece to form a convex contour in the work piece. The work piece, and subsequently formed contoured structure, can be metal or composite. The disclosed deep rolling systems and methods form, for example contoured aircraft panels, while also providing fatigue strength improvement and low level of work hardening during the forming process rather than as a post-production surface treatment.

A method for manufacturing a monolithic component with integral branching points, including providing a sheet metal comprising a first section and a second section, thinning, via rollforming, the first section of the sheet metal, splitting, via split-rollforming, the second section of the sheet metal in a plane parallel to a surface area of the second section, such that a first flange portion and a second flange portion is formed.

A rolled track link may comprise a central portion, a front portion, on a front side of the central portion, having a front portion planar upper surface and a pin bore, and a back portion, on a back side of the central portion, having a back portion planar upper surface that is offset from the front portion planar upper surface by a perpendicular distance along a height of the track link, and having a bushing bore. At each point along a length of the track link, a thickness of the track link is uniform along a width of the track link, other than at holes, including the pin bore and the bushing bore.