A method is provided for forming a flat metal blank as a workpiece in a forming die.

An automotive component manufacturing method includes a molding process of pressing a portion of a hollow tube formed from a metal material, or a composite material including a metal and a resin, so as to deform the portion of the hollow tube, from a tube outer side toward a tube inner side, to beyond an axial center of the hollow tube, and mold the portion of the hollow tube into a deformed section deformed with a concave profile; and a deformation process of deforming a location having a high level of residual stress in a closed cross-section configured by the deformed section so as to deform the location out-of-plane.

An automotive component manufacturing method includes a molding process of pressing a portion of a hollow tube formed from a metal material, or a composite material including a metal and a resin, so as to deform the portion of the hollow tube, from a tube outer side toward a tube inner side, to beyond an axial center of the hollow tube, and mold the portion of the hollow tube into a deformed section deformed with a concave profile; and a deformation process of deforming a location having a high level of residual stress in a closed cross-section configured by the deformed section so as to deform the location out-of-plane.

The controller controls the gas supply of the gas supply unit so as to maintain a pressure in a metal pipe material at a first pressure when a gas is supplied into the metal pipe material which is formed into a pipe portion in a main cavity portion in a state where an upper die and a lower die are joined to each other. It is possible to prevent pressure drop in the pipe portion caused by cooling of the pipe portion due to a contact between the dies, and the pipe portion. Thus, it is possible to suppress a decrease in a force for pressing the pipe portion against the dies. It is possible to suppress a decrease in adhesion between the pipe portion and the dies when the metal pipe is formed, and it is possible to suppress occurrence of variations in hardenability in the pipe portion.

The controller controls the gas supply of the gas supply unit so as to maintain a pressure in a metal pipe material at a first pressure when a gas is supplied into the metal pipe material which is formed into a pipe portion in a main cavity portion in a state where an upper die and a lower die are joined to each other. It is possible to prevent pressure drop in the pipe portion caused by cooling of the pipe portion due to a contact between the dies, and the pipe portion. Thus, it is possible to suppress a decrease in a force for pressing the pipe portion against the dies. It is possible to suppress a decrease in adhesion between the pipe portion and the dies when the metal pipe is formed, and it is possible to suppress occurrence of variations in hardenability in the pipe portion.

A method is provided for forming a flat metal blank as a workpiece in a forming die. The method may include providing a forming die with at least one cavity, and providing at least one blankholder for fixing a flat metal blank to the at least one cavity during the forming. The method may also include heating the flat metal blank to a solution heat treatment temperature specific to the flat metal blank while maintaining the forming die at the solution heat treatment temperature. The method may also include forming the workpiece from the flat metal blank at the solution heat treatment temperature.

A method is provided for forming a flat metal blank as a workpiece in a forming die. The method may include providing a forming die with at least one cavity, and providing at least one blankholder for fixing a flat metal blank to the at least one cavity during the forming. The method may also include heating the flat metal blank to a solution heat treatment temperature specific to the flat metal blank while maintaining the forming die at the solution heat treatment temperature. The method may also include forming the workpiece from the flat metal blank at the solution heat treatment temperature.

A forming system that forms a metal pipe by expansion in a die includes a heater that heats at least an end part of a metal pipe material, a fluid supply unit that supplies a fluid into the metal pipe material to expand the metal pipe material, and a controller that controls the heater and the fluid supply unit, the fluid supply unit has a nozzle that supplies the fluid from the end part of the metal pipe material into the metal pipe material, and the controller controls the heater so as to heat the end part of the metal pipe material at least before the supply of the fluid by the fluid supply unit, and controls the fluid supply unit so as to expand the end part of the metal pipe material.

A forming device includes a gas supply part supplying a gas into a metal pipe material held and heated between a first die and a second die paired with each other. A driving mechanism moves at least one of the first die and the second die in a direction in which the dies are combined together. A first cavity part is formed between the first die and the second die to form the pipe part. A second cavity part communicates with the first cavity part to form the flange part. A flange forming member can be allowed to advance or retreat in the second cavity part, and forms the flange part. A controller controls the gas supply of the gas supply part, the driving of the driving mechanism, and the advance or retreat of the flange forming member.

A forming device includes a gas supply part supplying a gas into a metal pipe material held and heated between a first die and a second die paired with each other. A driving mechanism moves at least one of the first die and the second die in a direction in which the dies are combined together. A first cavity part is formed between the first die and the second die to form the pipe part. A second cavity part communicates with the first cavity part to form the flange part. A flange forming member can be allowed to advance or retreat in the second cavity part, and forms the flange part. A controller controls the gas supply of the gas supply part, the driving of the driving mechanism, and the advance or retreat of the flange forming member.