A multi-stage incremental sheet forming system includes a forming tool, and at least one control unit in communication with the forming tool. The at least one control unit is configured to determine a convex hull of a target structure to be formed by the forming tool. The at least one control unit is further configured to operate the forming tool according to a first tool path in relation to an initial structure to form an intermediate structure having a shape based on the convex hull of the target structure. The at least one control unit is further configured to operate the forming tool according to a second tool path in relation to the intermediate structure to form one or more inward features into the intermediate structure to form the target structure.

A forging press apparatus includes: a die with a die hole into which a material is to be contained and a relief hole smaller in diameter than the die hole; a molding punch configured to press an inner portion inside a peripheral portion of the material contained in the die hole; and a pressing member provided around an outer periphery of the molding punch to press the peripheral portion. A method includes: loading the material into the die; and forging the cup structure shaped by pressing the inner portion inside the peripheral portion of the material with the molding punch to cause the peripheral portion of the material to be brought into contact with the pressing member, and a part of the material to be pushed out into the relief hole by the molding punch to form a projection while a space is secured below the projection.

A forging press apparatus includes: a die with a die hole into which a material is to be contained and a relief hole smaller in diameter than the die hole; a molding punch configured to press an inner portion inside a peripheral portion of the material contained in the die hole; and a pressing member provided around an outer periphery of the molding punch to press the peripheral portion. A method includes: loading the material into the die; and forging the cup structure shaped by pressing the inner portion inside the peripheral portion of the material with the molding punch to cause the peripheral portion of the material to be brought into contact with the pressing member, and a part of the material to be pushed out into the relief hole by the molding punch to form a projection while a space is secured below the projection.

A material including a metal sheet, a first plurality of raised and pointed structures, and a second plurality of raised and pointed structures is provided. The metal sheet includes first and second opposed sides, and a thickness between the first and second opposed sides. The first plurality of raised and pointed structures are gouged out of the first side of the metal sheet. The sheet is not perforated, and the raised and pointed structures of the first plurality have a height of between 150% and 300% of the thickness. The second plurality of raised and pointed structures are gouged out of the second side of the metal sheet.

The invention relates to a method for connecting at least two component layers by means of a connection element. the invention to provide a particularly advantageous method for connecting at least two component layers lying on top of each other through the creation of a pilot hole in at least one cover layer. The pilot hole in the form of a through hole is made in the at least one cover layer using only a plasma jet, which cover layer is at least temporarily held in place on the base layer. Holding the cover layer and the base layer temporarily fixed to each other will allow the connection element to be placed at the same position in the base layer where the pilot hole is made. Sufficiently large layers can thus be kept in a fixed position relative to one another solely using their weight and friction.

A vehicle structural member includes an elongate hollow member having an integrated structure, and supporting members joined to the elongate hollow member. The elongate hollow member includes: a first portion that includes a first pipe, a second pipe disposed outside the first pipe and extending along the first pipe, and a connection portion extending along the first pipe and the second pipe, formed integrally with the first pipe and the second pipe, and connecting the first pipe and the second pipe; and a second portion that includes the first pipe continuing from the first portion, and does not include the second pipe.

A vehicle structural member includes an elongate hollow member having an integrated structure, and supporting members joined to the elongate hollow member. The elongate hollow member includes: a first portion that includes a first pipe, a second pipe disposed outside the first pipe and extending along the first pipe, and a connection portion extending along the first pipe and the second pipe, formed integrally with the first pipe and the second pipe, and connecting the first pipe and the second pipe; and a second portion that includes the first pipe continuing from the first portion, and does not include the second pipe.

A vehicle component joining method includes, among other things, positioning a contact side of a first component adjacent a contact side of a second component, inserting a mechanical fastener into a cavity of the first component, and rotating the mechanical fastener to drive the mechanical fastener through an interface between the contact sides of the first and second components. The interface is disposed along an interface plane and the mechanical fastener is driven through the interface in a direction that is nonperpendicular to the interface plane.

The present invention relates to a method and tools for manufacturing of seamless tubular shapes, especially tubes and canisters. In the method of the invention the tubular shape is extracted from the flash continuously produced during the plunging of a consumable rod against a rigid anvil. The tools of the invention include a consumable rod; a non-consumable or consumable rigid anvil; first means for rotating the consumable rod and the non-consumable or consumable rigid anvil relatively with respect of each other; second means for plunging the consumable rod and the non-consumable or consumable rigid anvil relatively against each other; open die condition configuration for continuous production of flash during said plunging.

A material includes a sheet of metal having a first face and an opposed second face, and a metal grain direction. The first face is textured with a first set of texturing features. Each texturing feature of the first set includes, respectively, a groove cut into the first face and extending along a groove axis, and a barb extending from the groove and away from the first face. The texturing features of the first set are arranged in a plurality of rows, and the groove axes of the texturing features in a given row extend generally parallel to the given row. The rows are generally non-perpendicular to the grain direction.