Intellectual Property Office

Non-Confidential Disclosures

“Electrically Assisted Metal Forming Process”

PSU Inv. Disc. No 2006-3280

Keywords

Metal shaping/forming; sheet metal; hydroforming

Inventors:

John T. Roth, Albert Krause, Sergey Golovashchenko

Links:

http://www.ipo.psu.edu
http://www.erie.psu.edu/academic/engineering/faculty/jtr11

Background:

The extent to which metal parts may be formed by plastically deforming sheet metal blanks or tubular blanks is limited by the strength and the inherent formability of the metal. Complex parts that have pronounced recesses or protrusions may not be formed from a single blank if the formability of the metal is exceeded by the strain required for forming the part. In some instances, parts with complex geometries may require forming multiple parts separately and joining them together by spot welding, riveting, or otherwise fastening the panels together. Forming multiple parts that must be assembled together to create a combined part of the desired shape increases the number of parts and the costs associated with manufacturing the combined part. There is a need for a method and apparatus for forming extensively formed parts made in a single piece that are plastically deformable to the maximum extent.

Invention description:

The present invention relates to a method and apparatus for forming a sheet metal blank, a tubular blank, or a partially formed blank while pulses of current are applied, improving formability. Electrodes are attached to a forming tool to provide pulses of current which pass through at least a portion of the blank. The flow of current during a manufacturing process reduces the required deformation energy, improves part quality, and extends the range of manufacturing for a given workpiece material. Benefits of the process include reduced post deformation spring-back, increased workability, and increased tooling life. Application of electricity will improve the operations of sheet metal forming/stamping, forging, extrusion, drawing, rolling, cutting and machining. Figure 1 shows an example of the dramatic increase in elongation possible with the invention.

Advantages:

• Patent pending
  
• Requires smaller equipment and/or the use of less energy
  
• Reduction of costs associated with manufacturing of complex geometries and multiple parts
  

Contact:

Bradley A. Swope
Sr. Technology Licensing Officer
Intellectual Property Office
113 Technology Center
The Pennsylvania State Univ.
University Park, PA 16802-7000
Phone: (814) 863-5987
Fax: (814) 865-3591
E-mail:bradswope@psu.edu