A bumper beam made of at least one roll formed steel sheet is described. The bumper beam contains an upper beam and a lower beam extending in a transversal direction, the upper beam and the lower beam each having a closed cross-section defined by a front wall, a rear wall, an upper wall and a lower wall, the upper wall and the lower wall joining the front wall to the rear wall, and a central wall extending between the front walls, the rear walls of the upper beam and of the lower beam forming both the lower wall of the upper beam and the upper wall of the lower beam, the central wall extending in at least two different planes.

A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.

A bumper beam made of at least one roll formed steel sheet is described. The bumper beam contains an upper beam and a lower beam extending in a transversal direction, the upper beam and the lower beam each having a closed cross-section defined by a front wall, a rear wall, an upper wall and a lower wall, the upper wall and the lower wall joining the front wall to the rear wall, and a central wall extending between the front walls, the rear walls of the upper beam and of the lower beam forming both the lower wall of the upper beam and the upper wall of the lower beam, the central wall extending in at least two different planes.

A vehicle reinforcement beam is roll formed from a metal sheet to provide a multi-tubular reinforcement beam that includes two adjacent tubular sections that share a common center wall. The outer sections the metal sheet extend from opposing ends of the common center wall and are formed to enclose the adjacent tubular sections. An edge portion of the metal sheet that is bent to have a bend radius of about 3-9 mm, where the edge portions attach in abutting and continuous contact with the common center wall to form crevices between the adjacent tubular sections along the first and second faces. A weld is formed in each of the crevices to define crevice ribs in general alignment with and at each of the opposing first and second ends of the common center wall that are configured to improve bending strength and torsional strength of the reinforcement beam.

A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.

A multi-axis roll-forming system for forming a stepped diameter in a cylinder. The system includes a support configured to spin about a rotation axis while supporting a workpiece including a cylinder. A first actuator is configured to translate a first roller perpendicular to rotation axis. The first roller includes a truncated conical work surface configured to press against the inward-facing surface of the cylinder to angle it outward according to a slant angle of the truncated conical work surface.

A method and an installation for continuously shaping longitudinally slotted pipes from a flat material minimizes or avoids markings in the material by evenly introducing into the roll stand the rolling forces of at least two rolls acting successively on the flat material and/or by allowing the two successively acting rolls to align freely relative to one another.

The present disclosure relates to bumper beams having a closed cross-section, the closed cross-section being formed by one or more metal plates. The metal plates include a plurality of holes and a plurality of projections, wherein the projections engage with corresponding holes to retain the closed cross-section. The present disclosure further relates to rocker panels having a closed cross-section, the closed cross-section being formed by one or more metal plates, and the metal plates including a plurality of holes and a plurality of projections, wherein the projections engage with corresponding holes to retain the closed cross-section. The present disclosure further relates to methods of manufacturing such bumper reinforcing members and rocker panels.

A hollow profile and a method of producing the hollow profile from a hardenable steel alloy blank is disclosed having an L-shaped cross section with an upper vertical hollow chamber, and a lower horizontal hollow chamber, wherein the blank comes in abutment on an intermediate bridge area, forming a double layer. The hollow profile further includes, at least in regions, a tensile strength Rm greater than 1000 MPa.

A shaped roller for a profiling line, comprising a conical portion (2) and an end portion (3), concentric with respect to a rotating axis (Z), wherein the conical portion (2) is equipped with a vertex section (23), and wherein the end portion (3) has a greater diameter than the vertex section (23) that defines a shoulder from the surface of the first conical portion (2).