Systems and methods are described for roll-forming metal substrates. The metal substrates are subjected to induction heating during the roll-forming process by exposure to time-varying magnetic fields, such as by exposure to a rotating permanent magnet, or exposure to laser radiation from a laser source. Heating of the metal substrates allows improved formability or plasticity of the substrate in order to reduce or eliminate damage to the substrate during roll-forming to low bending radius to thickness ratios. Heating of the high-strength metal substrates can also function to temper the substrates and/or improve surface corrosion resistance and form high-strength end products with desirable properties.

A system (100) for a sheet metalworking is disclosed. The system (100) comprising a punch (1) connectable to a press (P), wherein the punch (1) is configured with a first electrical terminal (2). A die (3) configured with a die surface (DS), to support sheet metal (SM). A support member (4) movably disposed in the die (1), the support member (4) is provided with a second electrical terminal (5). The support member (4) and the punch (1) contacts a working portion (B) of the sheet metal (SM) at an axis (A-A) to supply electric current to a localized region (LR) of the working portion (B) for sheet metalworking.

A thermal-assisted method deforms plastically a high-strength material using a high-intensive heat source. The high-strength material may be a cold-rolled sheet aluminum of strength greater than 300 megapascal (MPa) or a cold-rolled sheet steel of strength greater than 1000 MPa. The cold-rolled sheet metal is heated just before bending to a temperature near or above the critical temperature for the material and is followed by rapid quenching after bending.

A system for forming a metal strip into a die having a predetermined shape through a series of forming operations is described herein. The system includes a base configured to support the metal strip as the metal strip undergoes the series of forming operations; a feeding device configured to advance the metal strip between each forming operation of the series of forming operations and grip the metal strip during each forming operation; a bending device configured to bend a portion of the metal strip extending from the feeding device as one of the series of forming operations; a forming head configured to house a pair of forming tools and provide features to the portion of the metal strip extending from the feeding device as one of the series of forming operations using the one or more forming tools; a robotic arm configured to selectively provide the one or more forming tools to the forming head; and a computing unit in communication with the robotic arm and configured to transmit a control signal to cause the robotic arm to retrieve the pair of forming tools and provide the pair of forming tools to the forming head.

Provided, among other things, is a method of cutting and folding a planar substrate with a focused laser beam, directed from above the substrate, to form a shape with features in 3-dimensions, the method comprising: (a) executing from above laser cuts to the planar substrate so as to provide one or more a releasable segments; (b) executing from above one or more laser-executed upward folds to bend all or a portion of a releasable segment; and (c) executing from above one or more laser-executed downward folds to bend all or a portion of a releasable segment; wherein the cuts and folds are structured so that precursors to the 3D shape remain attached to the substrate while sufficient cuts and folds are made to form the 3D shape, and wherein the planar substrate is immobile during said steps (a) through (c), or is only moved in the plane of the substrate.

The present disclosure relates to a local heat treatment system and a cold forming method using the same. The local heat treatment system includes a heating device configured to locally heat only a plastic deformation occurrence portion of a blank material to a predetermined temperature, a moving device configured to move the heating device to a position of a local heating region of the blank material, and a controller configured to control the heating device and the moving device.

A method for forming a dome used in a launch vehicle includes cutting a disk from a plate, the disk having a first disk diameter. The method also includes forming a bend in the disk, the bend applying a curvature to at least a portion of the disk, the disk having a second disk diameter after the forming. The method further includes performing a first heat-treating process to the disk. The method also includes performing a second heat-treating process to the disk. The method further includes machining the disk to remove at least a portion of a thickness of the disk.

A high strength member according to the present invention is the high strength member having a bending ridge line portion formed from a steel sheet, the member having a tensile strength of 1470 MPa or higher, a residual stress of 300 MPa or lower in an end surface of the bending ridge line portion, and a Vickers hardness (HV) of 200 or higher and 450 or lower in the end surface of the bending ridge line portion.

A system for forming a metal strip into a die having a predetermined shape through a series of forming operations is described herein. The system includes a base configured to support the metal strip as the metal strip undergoes the series of forming operations; a feeding device configured to advance the metal strip between each forming operation of the series of forming operations and grip the metal strip during each forming operation; a bending device configured to bend a portion of the metal strip extending from the feeding device as one of the series of forming operations; a forming head configured to house a pair of forming tools and provide features to the portion of the metal strip extending from the feeding device as one of the series of forming operations using the one or more forming tools; a robotic arm configured to selectively provide the one or more forming tools to the forming head; and a computing unit in communication with the robotic arm and configured to transmit a control signal to cause the robotic arm to retrieve the pair of forming tools and provide the pair of forming tools to the forming head.

In certain embodiments described herein, a heated line forming system includes a heating coil system configured to produce a heated line on a surface of a metal part. The heated line forming system also includes an air knife cooling system configured to maintain a dry area for the heated line, and to direct a coolant (e.g., cooling water, liquified gases such as liquid argon, solidified gases such as carbon dioxide snow, and so forth) around the heated line via a spray mechanism such that the coolant does not flow or splash into the heated line on the metal part. In certain embodiments, the heated line forming system includes multiple induction coils arranged along a line and spaced a short distance apart, but which, when operated simultaneously together, form a heated line on a surface of a metal part.