A method for manufacturing a semifinished product or component is disclosed in which a metal support embodied as a split strip is covered with at least one prepreg containing a thermally cross-linkable thermosetting matrix with endless fibers, the thermosetting matrix of the prepreg is pre-cross-linked by means of heating, and the metal support covered with the pre-cross-linked prepreg is formed into a semifinished product or component by means of roll forming, in order to enable plastic deformation in fiber-reinforced regions of the metal support, it is proposed that during the pre-cross-linking of the thermosetting matrix of the prepreg, its matrix is transferred into a viscosity state that is higher than its minimum viscosity and prior to reaching its gel point, the prepreg is formed together with the metal support.

An ultrasonically vibrated die comprises a generally cylindrical die ring supported by a coaxial resonant mounting tube. The die ring is vibrated in a radial bending mode of vibration, in which an end surface of the die ring oscillates between a concave and a convex state. The mounting tube joins the end surface of the die ring at a radius R where the amplitude of the oscillation of the end surface is at a minimum, in order to reduce transmission of the vibration into the mounting tube.

A forming die that includes a body, wherein the body of the forming die includes at least one opening created therein; at least one die segment, wherein the at least one die segment is adapted to be inserted into the at least one opening in the body of the forming die, and wherein the at least one die segment is further adapted to receive ultrasonic vibrations; and at least one geometric feature formed within the at least one die segment, wherein the at least one geometric feature affects the ultrasonic vibrations in a predetermined manner.

A draw die for use in a draw stage configured to process a work piece in a forming operation is provided. The draw die includes a first segment, a second segment positioned adjacent to the first segment, and an isolation material positioned between the first segment and the second segment and configured to substantially isolate the second segment from ultrasonic vibrations of the first segment.

The invention relates to a system for making a metal product, comprisinga lubrication source (225) for applying a first lubricant (235) on a punch side of a sheet metal blank (205);a controllable current source (250) for applying different amounts of current; anda punch (215) and a die (220) for drawing the sheet metal blank (205) into a metal product, wherein the controllable current source (250) is electrically coupled to one or more of the punch (215), the die (220), or a contact point for applying current through the first lubricant (235) while the sheet metal blank (205) is drawn by the punch (215) and the die (220) into the metal product and while the metal product is being ejected from the punch (215). The application further relates to a method for making a metal product with a such system. The invention relates also to a container manufacturing system (700), comprisinga cylindrical ram (720) comprising a ram body (722) and a ram nose on a distal end of the ram body (722), the ram nose engageable with abase of a container preform;a die (730) comprising an opening concentrically aligned with the cylindrical ram (720), the opening sized and shaped for receiving the container preform in response to the ram nose engaging with the base of the container preform and the cylindrical ram (720) driving the container preform through the die opening; andan ultrasonic device (740) coupled with the die (730), wherein the ultrasonic device causes the die (730) to vibrate while the cylindrical ram (720) drives the container preform through the die opening. The application further relates to a method for forming an aluminium container with such system and a die (730) for forming an aluminium container.

Described are techniques and systems for improving the reliability of metal forming operations, such as stamping or drawing processes. Lubricants that can have their lubricating properties changed in real time through the application of an electric current are used to modify the friction between the forming equipment and the metal product being formed, allowing for more precise control over forming and associated operations.

A method for reducing areas of friction within a forming die that includes identifying at least one region of interest in the forming die, wherein the at least one region of interest further includes a problematic aspect of a predetermined nature; designing a die segment corresponding to the at least one region of interest, wherein the die segment further includes at least one ultrasonic transducer embedded therein; modifying the forming die to receive the die segment; installing the die segment in the forming die and acoustically isolating the die segment from the remainder of the forming die; and energizing the ultrasonic transducer to provide ultrasonic energy to the die segment, wherein providing ultrasonic energy to the die segment addresses the problematic aspect of the at least one region of interest in the forming die.

An incremental sheet forming tool. The tool includes: a tool body; a tool head, rigidly attached to the body and having a punch; a housing provided in the body; an actuator, located in the housing and capable of producing a vibration in a first direction which can propagate to the punch); and at least one element for transforming the first direction of the vibration into a second direction of the vibration, as it is propagating to the punch.

A process of reducing internal defects or enhancing mechanical properties in local regions in a solidified casting utilizes the combination effect of compression, high-intensity ultrasound, and heat on improving the local microstructure. The casting is brought to predetermined temperatures where plastic deformation in the local regions of the casting is produced under controlled conditions to close voids, breakup oxide films, and refine solidification structure.