A formed material manufacturing method according to present invention includes the steps of forming a convex formed portion by performing at least one forming process on a surface treated metal plate, and performing ironing on the formed portion using an ironing mold after forming the formed portion. The ironing mold includes a punch that is inserted into the formed portion, and a die having a pushing hole into which the formed portion is pushed together with the punch. An inner peripheral surface of the pushing hole extends non-parallel to an outer peripheral surface of the punch, and the inner peripheral surface is provided with a clearance that corresponds to an uneven plate thickness distribution, in the pushing direction, of the formed portion prior to the ironing relative to the outer peripheral surface to ensure that an amount of ironing applied to the formed portion remains constant in the pushing direction.

An apparatus for forming and sealing an adjustable duct member for use in an air handling system. At least one work station accommodates a tapered work piece. A repositionable die is positioned relative to the work piece, and a cutting and forming assembly cooperates with the repositionable die to cut the work piece and form a coupling bead to reconnect the members together. A sealing assembly cooperates with the first repositioning die to seal the coupling bead in the first and second members. The work station includes an insertion channel having predetermined dimensions to accommodate at least a portion of the work piece. A clamping assembly is associated with the insertion channel to securely hold the tapered work piece at the predetermined position during the cutting and forming and sealing operations.

An apparatus for forming and sealing an adjustable duct member for use in an air handling system. At least one work station accommodates a tapered work piece. A repositionable die is positioned relative to the work piece, and a cutting and forming assembly cooperates with the repositionable die to cut the work piece and form a coupling bead to reconnect the members together. A sealing assembly cooperates with the first repositioning die to seal the coupling bead in the first and second members. The work station includes an insertion channel having predetermined dimensions to accommodate at least a portion of the work piece. A clamping assembly is associated with the insertion channel to securely hold the tapered work piece at the predetermined position during the cutting and forming and sealing operations.

A hydraulic roll bending machine and method includes loading a plate between top and bottom rollers, receiving a user input indicative of a desired plate radius, calculating a pre-bend radius for the plate based on the desired plate radius and information from the material database, providing a bending signal to the actuator to position the at least one bending roller relative to the top and bottom rollers based on the pre-bend radius, providing a feed signal to advance a leading portion of the plate against the at least one bending roller, determining an actual pre-bend radius of the leading portion of the plate, and calculating an adjustment to the material database based on a difference between the pre-bend radius and the actual pre-bend radius.

A helically wound tubular structure is disclosed. The tubular structure has a first sheet metal helically wound about a longitudinal axis, a second sheet metal having voids disposed therein helically wound about the longitudinal axis and coaxially about the first sheet metal, and a third sheet metal helically wound about the longitudinal axis and coaxially about the first sheet metal and the second sheet metal.

A tubular structure is disclosed. The tubular structure has a first sheet metal having a machine direction. The first sheet metal is convolutely wound about a longitudinal axis and has a tail portion. The tail portion of the first sheet metal is disposed upon and bonded to an immediately subjacent convolution of the first sheet metal.

An elongate tubular structure is disclosed. The elongate tubular structure has a first and second tubular structure wherein a first end of the first tubular structure is matingly and fasteningly engaged to a first end of the second tubular structure. The first and second tubular structures each have a first sheet metal having a machine direction being convolutely wound about a first longitudinal axis. The first sheet metal has a tail portion that is disposed upon and bonded to an immediately subjacent convolution of the first sheet metal to form the respective first and second tubular structures.

A pipe is formed by press molding a U-shaped member including a U-shaped cross section. The U-shaped cross section includes at least five curved portions. The curved portions include a center curved portion facing an opening of the U-shaped cross section defined by both edges of the U-shaped cross section; a first right curved portion; a second right curved portion; a first left curved portion; and a second left curved portion. At least the center curved portion, the first right curved portion, and the first left curved portion each have a radius of curvature smaller than a radius of curvature of a corresponding portion of the pipe cross section.

A pipe is formed by press molding a U-shaped member including a U-shaped cross section. The U-shaped cross section includes at least five curved portions. The curved portions include a center curved portion facing an opening of the U-shaped cross section defined by both edges of the U-shaped cross section; a first right curved portion; a second right curved portion; a first left curved portion; and a second left curved portion. At least the center curved portion, the first right curved portion, and the first left curved portion each have a radius of curvature smaller than a radius of curvature of a corresponding portion of the pipe cross section.

In a localized torsional severe plastic deformation method for conical tube metal, a desired region of a conical tube metal can be subjected to severe plastic deformation using molds in which roughness is formed at predetermined regions. The method includes roughening a predetermined region of each of the molds; sticking the conical tube metal only to the roughened regions of the molds; moving the lower mold toward the upper mold to apply a load to the conical tube metal; and rotating the molds to apply severe plastic deformation to the conical tube metal only at the regions stuck to the roughened regions of the molds.