Method for production of sheet metal components

Abstract

A process includes producing a group of automotive components by forming components having various global geometries via a common tooling configured to bend a blank sheet of metal to create a variable cross section profile, forming an addendum as an integral portion of each formed component, and altering the global geometries in a series of incremental deformations to create local geometries while each component is affixed to a deforming machine via the addendum.

What is claimed is: 
     
         1 . A process comprising:
 producing a group of automotive components by forming components having various global geometries via a common tooling configured to bend a blank sheet of metal to create a variable cross section profile;   forming an addendum as an integral portion of each formed component; and   altering the global geometries in a series of incremental deformations to create local geometries while each component is affixed to a deforming machine via the addendum.   
     
     
         2 . The process of  claim 1 , wherein the group of automotive components comprises one component type designated for different vehicle types. 
     
     
         3 . The process of  claim 2 , wherein the one component type comprises an underbody member, a roof cross member, a rail, or a rocket member. 
     
     
         4 . The process of  claim 1 , wherein the group of automotive components comprises different component types designated for one vehicle type. 
     
     
         5 . The process of  claim 1 , wherein the component has a longitudinal profile. 
     
     
         6 . The process of  claim 1 , wherein the variable cross section profile comprises a variable height cross section. 
     
     
         7 . The process of  claim 1 , wherein the addendum extends beyond the global geometry of the component. 
     
     
         8 . The process of  claim 1 , wherein the addendum has a shape universal for each component of the group of the components. 
     
     
         9 . The process of  claim 1 , wherein the addendum is removed after formation of the local geometries. 
     
     
         10 . The process of  claim 1 , wherein the global geometries and the local geometries are created separately via different tooling. 
     
     
         11 . A method comprising:
 producing a group of various automotive longitudinal components by utilizing a common tool to form a variable cross section profile by bending a sheet metal for each component of the group in a first process;   connecting each deformed metal sheet to a removable section; and   further altering the profile of the deformed metal sheet in a series of incremental deformations in a second process to create the longitudinal component while the sheet metal is attached to a deforming machine via the removable section.   
     
     
         12 . The method of  claim 11 , wherein the first and second processes are performed by different machines and tooling. 
     
     
         13 . The method of  claim 11 , wherein the bending forms depressions in a vertical surface of the sheet metal. 
     
     
         14 . The method of  claim 11 , wherein the incremental deformations include bending a horizontal surface of the sheet metal. 
     
     
         15 . The method of  claim 11 , wherein the removable section is laser trimmed after the second process. 
     
     
         16 . The method of  claim 11 , wherein the first process utilizes flexible roll forming and the second process utilizes incremental forming. 
     
     
         17 . A process of forming automotive sheet metal components, the process comprising:
 creating a global geometry of a first longitudinal sheet metal component by forming a variable cross section profile in a blank sheet of metal;   altering the global geometry of the first component in a series of incremental deformations to create local geometries; and   creating global and local geometries of a second component by utilizing tooling which formed the first component, wherein the first and second components differ.   
     
     
         18 . The process of  claim 17 , wherein the first and second components are longitudinal components having at least one different dimension. 
     
     
         19 . The process of  claim 17 , wherein the first and second components are roof side railings having at least one different portion of the profile. 
     
     
         20 . The process of  claim 17 , wherein the first and second components differ in length, height, depth of depression of at least one portion of the components, or a combination thereof.