WO2017019855A1 - Stamping die - Google Patents

Abstract

A forming system includes a first die assembly having a first die surface, a second die assembly having a second die surface; a movable die block having a third die surface; and a cooling system. The first die surface, the second die surface and the third die surface are configured to cooperate to form a die cavity therebetween so as to receive a work piece therein. A relative movement between the first die assembly and the second die assembly along a first axis moves the die cavity between an open position and a closed position. The die block is movable relative to the first die assembly in a direction transverse to the first axis and applies a force to the work piece that is predominantly transverse to forces applied to the work piece by the first die assembly and the second die assembly.

Description

STAMPING DIE

[0001] This application claims the priority to U.S. Patent Application No. 62/198,980, filed July 30, 2015, which is hereby incorporated by reference in its entirety.

FIELD

[0002] The present patent application relates to a system and method for forming a sheet metal member.

BACKGROUND

[0003] Vehicle manufacturers strive to provide vehicles that are increasingly stronger, lighter and less expensive. One proposed solution includes the use of heat-treated sheet steel panel members to form the vehicle body panel members. In some applications, the sheet steel panel members are formed in a forming process and subsequently undergo a heat-treating operation. This two-stage processing may be disadvantageous in that the additional operation may add significant cost and time.

[0004] As an alternative to a process that employs a discrete heat-treating operation, it is known that certain materials, such as boron steels, may be formed and quenched in a hot forming die system. In this regard, a pre-heated sheet stock may be typically introduced into a hot forming die system, formed to a desired shape and quenched subsequent to the forming operation while in the die system to thereby produce a heat treated component. The known hot forming dies for performing the hot forming and quenching steps typically employ water cooling passages (for circulating cooling water through the hot forming die system) that are formed in a conventional manner.

[0005] For example, formed components or parts can be quenched during the forming stage/procedure to ensure transformation from Austenite to Martensite. Cooling should be performed relatively quickly to allow for such transformation to occur and to reduce cycle time. There may be a poor contact/pressure on sidewall(s) of the formed component that results in a low coefficient of heat transfer and thus cooling rates may not be fast enough to reach Martensite. This may cause certain areas of the formed component to not meet desired mechanical properties. Alternately, even if the quenching time is sufficient to reach Martensite, there is still a desire to cool even more quickly to reduce cycle time of the cooling (and hence entire forming) operation.

[0006] The present patent application provides improvements to the hot forming systems and hot forming operations.

SUMMARY

[0007] One aspect of the present patent application provides a forming system that includes a first die assembly having a first die surface, a second die assembly having a second die surface, a movable die block having a third die surface, and a cooling system operatively associated with the first die assembly, the second die assembly and the movable die block. The first die surface, the second die surface and the third die surface are configured to cooperate to form a die cavity therebetween so as to receive a work piece therein. Relative movement between the first die assembly and the second die assembly along a first axis moves the die cavity between an open position and a closed position. The die block is movable relative to the first die assembly in a direction transverse to the first axis, and the die block applies a force to the work piece that is predominantly transverse to forces applied to the work piece by the first die assembly and the second die assembly.

[0008] Another aspect of the present patent application provides a method of forming a sheet metal member in a forming system is provided. The forming system includes a first die assembly having a first die surface, a second die assembly having a second die surface, a movable die block having a third die surface, and a cooling system operatively associated with the first die assembly, the second die assembly and the movable die block. The first die surface, the second die surface and the third die surface are configured to cooperate to form a die cavity therebetween so as to receive a work piece therein. The method includes moving the first die assembly relative to the second die assembly along a first axis to move the die cavity from an open position to a closed position, moving the die block relative to the first die assembly in a direction transverse to the first axis, and applying a force to the work piece with the die block that is predominantly transverse to forces applied to the work piece by the first die assembly and the second die assembly.

[0009] While the present disclosure can be used for forming automobile body panels, the same system and method can be used to form sheet steel that can be used for other applications. [0010] These and other aspects of the present patent application, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. In one embodiment of the present patent application, the structural components illustrated herein are drawn to scale. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the present patent application. It shall also be appreciated that the features of one embodiment disclosed herein can be used in other embodiments disclosed herein. As used in the specification and in the claims, the singular form of "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a schematic diagram of a hot stamping/forming system in accordance with an embodiment of the present patent application;

[0012] Figure 1A is a flow diagram of a method for forming a body member using the forming system in accordance with an embodiment of the present patent application;

[0013] Figures 2 and 3 are schematic diagrams of a hot stamping/forming system in accordance with another embodiment of the present patent application;

[0014] Figures 4 and 5 are schematic diagrams of a hot stamping/forming system in accordance with yet another embodiment of the present patent application; and

[0015] Figure 6 shows a sectional view of an upper die assembly of the hot stamping/forming system shown in Figures 4 and 5.

DETAILED DESCRIPTION

[0016] Figure 1 shows a forming system 10 for producing a sheet metal part, such as a vehicle body member or panel. The forming system 10 may be a hot forming system or a stamping die system. Referring to Figure 1, the forming system 10 includes a first die assembly 12, a second die assembly 14, a movable die block 16 and a cooling system 18 operatively associated with the first die assembly 12, the second die assembly 14, and the movable die block 16. [0017] In illustrative embodiment, the first die assembly 12 is shown as an upper die assembly. In another embodiment, the first die assembly 12 may be a lower die assembly. The first die assembly 12 includes a first die shoe or die holder 20, a first die body 22, and a first die surface 24. The upper die assembly 12 may be mounted in a stamping press or ram (not shown) to enable upwards and downwards movement of the upper die assembly 12. The stamping press or press ram may be driven hydraulically or mechanically (e.g., by an electric motor).

[0018] In one embodiment, the first die shoe or die holder 20 may be a support member, block or plate of the forming system 10 that secures a punch retainer (not shown), which is a device used to mount the first die body or punch 22 on the first die shoe or die holder 20. In one embodiment, the punch retainer is optional and the first die body or punch 22 is directly mounted on the first die shoe or die holder 20. In one embodiment, the first die shoe or die holder 20 may be made of a metal material.

[0019] In one embodiment, the first die body 22 may be referred to as a punch. In one embodiment, the first die body 22 may be formed of a heat conducting material such as tool steel, in particular DIEVAR®, which is marketed by Bohler-Uddeholm Corporation of Rolling Meadows, 111., or commercially available H-l 1 or H-13. In one embodiment, the first die body 22 may also include a plurality of cooling structures or channels 26 in at least a portion thereof. In one embodiment, the first die surface 24 may include a complex forming die surface.

[0020] In illustrative embodiment, the second die assembly 14 is shown as a lower die assembly. In another embodiment, the second die assembly 14 may be an upper die assembly. In one embodiment, the second die assembly 14 includes a second die shoe or die holder 28, a second die body 30, and a second die surface 32.

[0021] In one embodiment, the second die shoe or die holder 28 may be a support member, block or plate of the forming system 10 that secures a die retainer (not shown), which is a device used to mount the second die body or die 30 on the second die shoe or die holder 28. In one embodiment, the die retainer is optional and the second die body or die 30 is directly mounted on the second die shoe or die holder 28. In one embodiment, the second die shoe or die holder 28 may be made of a metal material.

[0022] In one embodiment, the second die body 30 may be referred to as a die. In one embodiment, the second die body 30 may be formed of a heat conducting material such as tool steel, in particular DIEVAR®, which is marketed by Bohler-Uddeholm Corporation of Rolling Meadows, 111., or commercially available H-l 1 or H-13. In one embodiment, the second die body 30 may also include a plurality of cooling structures or channels 34 in at least a portion thereof. In one embodiment, the second die surface 32 may include a complex forming die surface.

[0023] The movable die block 16 of the forming system 10 includes a third die surface 36. The first die surface 24 of the first die assembly 12, the second die surface 32 of the second die assembly 14 and the third die surface 36 of the movable die block 16 are configured to cooperate to form a die cavity 38 therebetween so as to receive a work piece 40 therein. In one embodiment, the die cavity 38 is configured to have a shape that corresponds to a final shape of the work piece 40 after the hot forming operation/procedure. In the illustrative embodiment shown, the cavity and shape of the part or work piece will have a tophat cross-sectional configuration.

[0024] As used herein, the term "die surface" refers to the portion of the exterior surface of a die assembly that forms a hot formed component and comes in direct contact with the portions of the work piece. Moreover, the term "complex die surface" as used in this description means that the die surface has a three-dimensionally contoured shape.

[0025] In the illustrative embodiment, the first die surface 24 may be generally horizontal die surface, while the second die surface 32 and the third die surface 36 may include a combination of generally vertical die surfaces and generally horizontal die surfaces. In another embodiment, the first die surface 24, the second die surface 32 and the third die surface 36 may include a combination of generally vertical die surfaces, generally horizontal die surfaces, generally angular die surfaces, generally arcuate die surfaces and/or generally other contour shaped die surfaces.

[0026] In one embodiment, the work piece 40 may be a sheet metal blank, which may be formed of a heat-treatable steel, such as boron steel. In another embodiment, the work piece 40 may be stamped from a sheet of hardenable steel, such as Usibor®1500P or Usibor® 1500, boron steel or any suitable hot stamp press hardened material. In one embodiment, the work piece 40 may be pre-shaped specifically for producing a desired shaped hot formed product, such as, for example, by an additional cutting procedure or an additional cold forming procedure. In one embodiment, the additional cutting procedure or additional cold forming procedure may be optional. In one embodiment, the work piece 40 may be a substantially four-sided, rectangular configuration. It should be appreciated, however, that the present application is not limited to sheet metal blanks of such configuration. [0027] Relative movement between the first die assembly 12 and the second die assembly 14 along a first axis A— A moves the die cavity 38 between an open position and a closed position. In one embodiment, the first axis A— A may be a longitudinal axis of the forming system 10. In one embodiment, the upper/first die assembly 12 is movable with respect to the lower/second die assembly 14 from an open position in which the die assemblies 12 and 14 are separated from each other to a closed position in which the die assemblies 12 and 14 form the closed die cavity 38. In one embodiment, the second die assembly 14 is fixedly mounted in the forming system or the stamping press. In the illustrative embodiment, the first die assembly 12 is movably mounted with respect to the fixed second die assembly 14. That is, the first die assembly 12 is configured to move downwardly along the first axis A— A such that the first die body 22 and the movable die block 16 cooperate with the second die assembly 14 to form the closed die cavity 38 therebetween. However, it is contemplated that the relative movement of the die assemblies may be accomplished through movement of either the upper/first die assembly 12, or the lower/second die assembly 14, or both, with respect to each other.

[0028] In one embodiment, the first die assembly 12 and the second die assembly 14 may be mounted in the stamping press. The stamping press may be configured to close the first and second die assemblies 12 and 14 in a die action direction (i.e., along or parallel to the first axis A— A) to deform the work piece 40 received in the die cavity 38 so as to form and optionally trim a hot formed member. In one embodiment, the stamping press may be configured to maintain the die assemblies 12 and 14 in a closed relationship for a predetermined amount of time to permit the formed member to be cooled to a desired temperature.

[0029] In one embodiment, the movable die block 16 may be referred to as a cam slide member. In one embodiment, the movable die block 16 of the forming system 10 may be part of the first die assembly 12. In one embodiment, as shown in Figure 1, the movable die block 16 may include a first movable die block 16a and a second movable die block 16b. The first movable die block 16a and second movable die block 16b are positioned on either side of the first die body 22. In one embodiment, the first movable die block 16a and second movable die block 16b are mounted on the first die shoe or die holder 20 of the first die assembly 12.

[0030] In the illustrative embodiment, one movable die block is shown on each side (i.e., right side and left side) of the forming system 10. However, it is contemplated that the number of movable die blocks on each side (i.e., right side and left side) of the forming system 10 may vary. For example, in one embodiment, the forming system may include only one die block. In another embodiment, the forming system 10 may include a two movable die blocks per side configuration, that is, two movable die blocks 16 on the right side and two movable die blocks 16 on the left side. In another embodiment, the forming system 10 may include a three movable die blocks per side configuration with three movable die blocks 16 on the right side and three movable die blocks 16 on the left side. In one embodiment, the width of each movable die block in the two movable die blocks per side configuration is wider than the width of each movable die block in the three movable die blocks per side configuration. In one embodiment one or more die blocks can be provided in the lower die structure (which can in such instance be considered the first die assembly), rather than the upper die structure.

[0031] In one embodiment, as shown in Figure 1, wear plates or members 42 are provided at the interface between the movable die block 16 and the fixed upper/first die shoe or die holder 20. In one embodiment, the wear plates or members 42 may be made from hardened steel material. The wear plates or members 42 may be configured to provide guide and wear surfaces between the movable die block 16 and the fixed upper/first die shoe or die holder 20. That is, the wear plates or members 42 are configured to provide guide and wear surfaces to the movable die block 16 as the movable die block 16 moves relative to the first die body 22 and the first die assembly 12. In one embodiment, wear plates or members 42a and 42b are provided at the interface between the fixed upper/first die shoe or die holder 20 and the respective movable die block 16a and 16b.

[0032] In one embodiment, the die block 16 is movable relative to the first die assembly 12 in a direction transverse to the first axis A-A. In one embodiment, the die block 16 is movable relative to the first die body 22 in a direction transverse to the first axis A-A. In one embodiment, the movement of the die block 16 relative to the first die assembly 12 and/or first die body 22 is a linear sliding movement in a direction transverse to the longitudinal axis A-A. In one embodiment, the die block 16 is movable relative to the first die assembly 12 and/or first die body 22 in a direction perpendicular to the longitudinal axis A-A of the forming system 10.

[0033] In the illustrative embodiment, the die cavity 38 is in the closed position. When the die cavity 38 is in the closed position, the first and second die surfaces 24 and 32 apply forces F to the work piece 40 in a direction generally corresponding to the first axis A— A. That is, the first and second die surfaces 24 and 32 apply the forces F to the work piece 40 in a direction generally parallel to or along the first axis A— A. In one embodiment, when the die cavity 38 is in the closed position, portions 36h of the third die surface 36 and portions 32hi of the second die surface 32 apply the forces F to the work piece 40 in a direction generally corresponding to, along or parallel to the first axis A— A. In one embodiment, the portions 36h of the third die surface 36 and the portions 32hi of the second die surface 32 may be generally horizontal die surfaces.

[0034] In one embodiment, the die block 16, 16a, or 16b applies a force SF to the work piece 40 that is predominantly transverse to the forces F applied to the work piece by the first die assembly 12 and the second die assembly 14. In one embodiment, the die block 16 applies the force SF to the work piece that is perpendicular to the forces F applied to the work piece 40 by the first die assembly 12 and the second die assembly 14. In another embodiment, the die block 16 applies the force SF to the work piece 40 that is angular to the forces F applied to the work piece 40 by the first die assembly 12 and the second die assembly 14. In one embodiment, the angle between the force SF applied to the work piece 40 by the die block 16 and the forces F applied to the work piece 40 by the first die assembly 12 and the second die assembly 14 may range between about 30 and 150 degrees. In another embodiment, the angle between the force SF applied to the work piece 40 by the die block 16 and the forces F applied to the work piece 40 by the first die assembly 12 and the second die assembly 14 may range between about 60 about 120 degrees.

[0035] In one embodiment, the two moveable die structures (i.e., first die body 22 and movable die block 16) and the single fixed die structure (i.e., second die body 30) together define the die cavity 38 of the forming system 10. Relative movement between the moveable die structures 22 and 16 and the single fixed die structure 30 closes the die cavity 38. After the die cavity 38 is closed, movement of the movable die structure 16 relative to the moveable die structure 22 applies a force on the work piece 40 that is predominantly transverse to forces applied to the work piece 40 by the first die assembly 12 and the second die assembly 14. This force provides a good contact/pressure on sidewall(s) of the formed component that results in a high coefficient of heat transfer and thus cooling rates that are fast enough to reach Martensite.

[0036] The first die assembly 12, the second die assembly 14 and the movable die block 16 are operatively coupled to the cooling system 18 such that the first die assembly 12, the second die assembly 14 and the movable die block 16 are configured to cool the work piece 40 in contact therewith when the die cavity 38 is closed. For example, the first die body 22, the second die body 30 and the movable die block 16 are operatively coupled to the cooling system 18.

[0037] The cooling system 18 may include a source of cooling fluid. In one embodiment, cooling fluid may include water, oil, saline, gas or other fluid medium. Cooling fluid, provided by the cooling system 18, may be continuously circulated through the cooling channels or structures to cool the die assemblies 12 and 14 and the movable die block 16. In one embodiment, the cooling system 18 may include a reservoir/chiller. In one embodiment, the cooling system 18 may include a pressure source or a fluid pump for forcing the cooling fluid through the cooling channels or structures. In one embodiment, the cooling fluid may be cycled in a continuous, uninterrupted manner, but it will be appreciated that the flow of cooling fluid may be controlled in a desired manner to further control the cooling of the die surfaces. It may be appreciated that circulating cooling fluids cools the die assemblies 12 and 14 and the movable die block 16, and that the cooled die assemblies 12 and 14 and the cooled movable die block 16, in turn, quench and cool the hot formed member.

[0038] In one embodiment, the first die body 22, the second die body 30 and the movable die block 16 may include cooling channels or structures 26, 34 and 44, respectively, that are constructed and arranged to carry a cooling fluid. In one embodiment, the cooling channels or structures may be formed by techniques such as gun drilling that yield straight channels extending through the respective die bodies and/or movable die block(s). In one embodiment, the cooling channels or structures are formed by gun drilling the cooling channels through one or two sides of the respective die bodies and/or the movable die block(s).

[0039] In one embodiment, each cooling channel or structure 26 may be offset from the die surface 24 by a first predetermined distance and this distance may be consistent along the length of the cooling channels 26. Similarly, each cooling channel 34 may be offset from the die surface 32 by a second predetermined distance, which may be different from the first predetermined distance, and this distance may be consistent along the length of the cooling channels 34. Similarly, each cooling channel 44 may be offset from the die surface 36 by a third predetermined distance, which may be different from the first predetermined distance and/or second predetermined distance, and this distance may be consistent along the length of the cooling channels 44. In another embodiment, the first, second and third predetermined distance may be the same. [0040] The distance between the cooling channels 26, 34, and 44 and their respective complex die surfaces 24, 32 and 36 as well as the mass flow rate of the cooling fluid and the temperature of the fluid are selected to control the cooling of the lower and upper die assemblies 12 and 14 and the movable die block 16 such that the hot-stamped component is quenched in a controlled manner consistently across its major surfaces to cause a phase transformation to a desired metallurgical state (i.e., Martensite). In one embodiment, the blank or work piece 40 is heated such that its structure is substantially (if not entirely) composed of austenite, the heated blank/work piece 40 is formed between the lower and upper die assemblies 12 and 14 and the movable die block 16. The hot-stamped component is quenched by the lower and upper die assemblies 12 and 14 and the movable die block 16 prior to the ejection of the hot-stamped component from the forming system 10. In this regard, the lower and upper die assemblies 12 and 14 and the movable die block 16 function as heat sinks to draw heat from and thereby quench the hot-stamped component in a controlled manner to cause a desired phase transformation (e.g., to Martensite) in the hot-stamped component and optionally to cool the hot- stamped component to a desired temperature.

[0041] In one embodiment, the forming system 10 may include a pair of cam driver members 46 (46a, 46b) and a pair of gas cylinder springs 48 (48a, 48b). In another embodiment, instead of the gas cylinder springs, the forming system may use any other biasing devices or mechanisms. In one embodiment, the force applied by the gas cylinder springs may be different from the force applied by the stamping press or ram.

[0042] In one embodiment, the gas cylinder spring 48 includes a cylinder that is sealed on both ends. The cylinder also includes a shaft connected to a piston reciprocating within the cylinder and extending out one end of the cylinder. In one embodiment, the forming system 10 includes a manifold configured for supplying gas or nitrogen under pressure to the cylinder and a pressure sensor configured to be operatively coupled to the manifold for providing a pressure signal of gas or nitrogen in the manifold.

[0043] The shaft or the piston extension is operatively connected to the cam driver member 46. The gas may be nitrogen or other similar inert gases. The pressure provided by the gas applies force to the piston and causes the shaft to be extended. In one embodiment, the amount of force applied by the cylinder may be varied to compensate for any material thickness discrepancies found in the work piece 40. The gas cylinder spring 48 is configured to be compressed by the cam driver member 46. The gas cylinder spring 48 is also configured to return the cam driver member 46 to its original position (inward towards the center of the forming tool) after the cam driver member 46 has been moved away from the center of the forming tool during the forming procedure. In one embodiment, the gas cylinder spring 48 may be configured to restrict or control the (horizontal) movement of the cam driver member 46 with respect to the movable die block 16. In one embodiment, the gas cylinder spring 48 may be configured to help compensate for any material thickness discrepancies found in the work piece 40.

[0044] Each cam driver member 46 is movable with respect to the lower die assembly 14. Each cam driver member 46 is operatively associated with a nitrogen cylinder spring 48 and is mounted for horizontal movement with respect to the lower die assembly 14 by the associated nitrogen cylinder spring. That is, each nitrogen cylinder spring 48 is configured to be expandable and retractable to affect the movement of the associated cam driver member 46 relative to the second die assembly 14. Each nitrogen cylinder spring 48 is configured to affect the movement of the associated cam driver member 46 towards and away from the first and the second die bodies 22 and 30. In one embodiment, the movement of the cam driver member relative to the lower die assembly 14 is a linear sliding movement in a direction transverse or perpendicular to the longitudinal axis A-A of the forming system 10.

[0045] In one embodiment, the cam driver member 46 includes an upwardly facing slanted cam surface 50 which is constructed and arranged to cooperate or engage with a downwardly facing slanted cam surface 52 of the movable die block 16.

[0046] As shown in Figure 1, wear plates or members 54 (54a, 54b) are provided at the interface between each movable cam driver member 46 and the fixed lower die shoe structure 28. In one embodiment, the wear plates or members 54 may be made from hardened steel material. The wear plates or members 54 may be configured to provide guide and wear surfaces between the movable cam driver member 46 and the fixed lower/second die shoe or die holder 28. That is, the wear plates or members 54 are configured to provide guide and wear surfaces to the movable cam driver member 46 as the cam driver member 46 moves relative to the fixed lower/second die shoe or die holder 28.

[0047] The operation of the forming system 10 will now be described.

[0048] In one embodiment, as shown in Figure 1A, a method 1000 of forming a sheet metal member in the forming system 10 is provided. In one embodiment, the sheet metal member may include a vehicle body member or panel. In one embodiment, the method 1000 may include procedures 1002-1004. For example, at procedure 1002, the first die assembly 12 is moved relative to the second die assembly 14 along a first axis A-A to move the die cavity 38 from an open position to a closed position. At procedure 1004, the die block 16 is moved relative to the first die assembly 12 in a direction transverse to the first axis A-A. At procedure 1006, a force is applied to the work piece 40 with the die block 16 that is predominantly transverse to forces applied to the work piece 40 by the first die assembly 12 and the second die assembly 14. Each of these procedures 1002-1004 and other optional/additional procedures of the method 1000 will be described in detail below.

[0049] When the upper/first die shoe or die holder 20 is withdrawn, by the stamping press or ram, to its highest position, the die cavity is the open position. In one embodiment, the die cavity is in the open position, when the upper/first die shoe or die holder 20 is withdrawn to an intermediate position. As the upper/first die body 22 and the movable die block 16 are operatively coupled to the upper/first die shoe or die holder 20, the upper/first die body 22 and the movable die block 16 are also withdrawn to their highest positions along with the upper/first die shoe or die holder 20. In one embodiment, the upper die assembly 12 is moved to a die/lowered/closed position, with respect to the lower/second die body 30, in order to stamp or form the work piece 40 to a desired configuration. In one embodiment, the upper die assembly 12 is moved to a die/lowered/closed position by the stamping press or ram.

[0050] When the die cavity is the open position, the nitrogen cylinder spring 48 applies pressure or force on the cam driver member 46 sliding it inwards towards the center of the forming system 10 (and towards the second die assembly 14). In one embodiment, the nitrogen cylinder springs 48a and 48b are configured to apply pressure to the associated cam driver members 46a and 46b sliding them in the direction of arrows CDA and CDB, respectively towards the center of the forming system 10. That is, prior to the beginning of the next forming cycle, the gas cylinder springs are energized to move the associated cam driver members to their original positions.

[0051] The forming procedure begins with the configuration in which a pre-cut blank sheet of metal material or work piece 40 is placed upon the lower die body 30, when the die cavity is the open position. In particular, the underside of the work piece 40 is laid to rest upon an upwardly facing, lower clamping surface 32 of the lower die body 30. [0052] In one embodiment, the work piece 40 is heated to an austenitizing temperature during the hot forming procedure. The work piece 40 (e.g., stamped or pre-shaped) is heated to the austenite state. For example, the work piece 40 is heated in an oven or a furnace (e.g., a roller- hearth or a batch style) to a temperature above the Ac3 temperature. In one embodiment, the work piece 40 may be pre-heated to a predetermined temperature, such as about 930 °C. In one embodiment, the work piece 40 may be pre-heated to a predetermined temperature, such as about 900 °C. In one embodiment, the work piece 40 is heated such that its structure is substantially (if not entirely) composed of austenite. Once the work piece 40 is in the austenite state, the work piece 40 may be transferred quickly/rapidly to the die assemblies 12 and 14.

[0053] After the work piece 40 is mounted on the lower die body 30, the die assemblies 12 and 14 may then be brought together (i.e., closed) in the die action direction via the stamping press or ram to cause the hot formed member to be formed. For example, the upper die shoe 20 is lowered (to its die position) by the stamping press or ram until a downwardly facing, lower clamping surface 24 of the upper die body 22 engages the upwardly facing surface of the sheet metal blank 40 and/or a downwardly facing, lower clamping surface 36h or 36 of the movable die block 16 engages the upwardly facing surface of the sheet metal blank 40 such that the work piece 40 is sandwiched between the die surface 24 of the upper die body 22, the die surface 36 of the movable die block 16 and the die surface 32 of the lower die body 30.

[0054] The lowering of upper die shoe 20 effects lowering of the upper die body 22 and the movable die block 16. In one embodiment, the movement of the movable die block 16 is a linear longitudinal downwardly movement. In one embodiment, the movement of the movable die block 16 is a vertical movement. In one embodiment, the movement of the movable die block 16 is in the direction of an arrow DF. As the upper die assembly 12 is lowered from its highest or intermediate position to its die position, the downwardly facing slanted cam surface 52 of the movable die block 16 engages or contacts the upwardly facing slanted cam surface 50 of the cam driver member 46. That is, as the movable die block 16 moves in the downwardly direction, the upwardly facing slanted cam surface 50 of the cam driver member 46 slidingly engages and bears against the downwardly facing slanted cam surface 52 of the movable die block 16 thereby advancing the movable die block 16 in a direction transverse to the axial downwardly direction of the movement of the movable die block 16. In one embodiment, the movement of the movable die block portion 16 is a transverse or lateral movement (towards the center of the forming system 10). In another embodiment, the movement of the movable die block 16 is a linear transverse or lateral movement (towards the center of the forming system 10). In one embodiment, the movement of the movable die block portion 16 is in the direction of an arrow S,

[0055] The engagement of the downwardly facing slanted cam surface 52 and the upwardly facing slanted cam surface 50 causes a camming effect on the movable die block 16 to drive the movable die block 16 against the lower die body 30. The inwardly transverse movement of the movable die block 16 exerts a force on the work piece 40 received in the die cavity 38. In one embodiment, the movable die block 16 is configured to apply pressure to the side walls of the work piece 40 received in the die cavity 38 (or the formed part).

[0056] Thus, the downward axial force of the movable die block 16 is translated into a side or laterally applied force on the work piece 140 by the die block 16. The arrangement of the cam driver member and the movable die block 16 are configured to convert the axial or longitudinal movement of the movable die block 16 into a lateral or transverse movement of translation (of the movable die block 16) so as to apply a transverse force on the work piece 40 received in the die cavity 38. In one embodiment, the force may be translated from downward (of the movable die block 16) to side or lateral (on the side walls of the work piece 140) by about 90 degree. In another embodiment, the force may be translated from downwards to side or lateral by about 30 to 150 degree. In another embodiment, the force may be translated from downwards to side or lateral by about 60 to 120 degree.

[0057] The cam driver member 46 is configured to force the movable die block 16 against the lower die body 30 creating pressure against the work piece 40. Urging the die surface 36 of the movable die block 16 tightly against its adjoining contact surface of the work piece 40 increases the area of contact between the movable die block 16 and the work piece 40, and provides an improved heat transfer path between the work piece 40 and the movable die block 16.

[0058] For example, the movable die block 16 is configured to movable relative to the first die assembly 12 (including the upper/first die show or holder 20 and the upper/first die body 22) to apply or exert a contact pressure force on portions of the work piece 40 that are in direct contact with the third die surface 36 of the movable die block 16 so as to increase thermal conductivity or heat transfer from the work piece 40 to the movable die block 16. The forming system 10 may be configured to provide good contact between the die surface 36 of the movable die block 16 and its adjoining contact surface of the work piece 40 so as to achieve uniform, contact pressure across the work piece 40. The camming action has effected displacement of the movable die block 16 so as to impose maximum contact pressure between the work piece 40 and the movable die block 16. In one embodiment, the movable die block 16 is configured to apply the contact pressure force on the side walls of the formed component at the bottom of the press ram's downward stroke. That is, the movable die block 16 is configured to contact the side walls of the formed component under pressure at the bottom of the downward stroke. In one embodiment, increased force applied by the third die surface 36 against the work piece 40 increases thermal transfer between the third die surface 36 and the work piece 40.

[0059] As the die assemblies 12 and 14 close (i.e., the first die body 22 and the movable die block 16 cooperate with the second die assembly 14 to form the closed die cavity 38 therebetween), the movable die block 16 is configured to apply pressure through the cam driver member 46 and compress the nitrogen cylinder 48.

[0060] Thus, the forming system 10 on the die close applies a pressure on the side walls or portions of the work piece 40 that are in direct contact with the movable die block 16. The pressure is applied via the gas cylinder springs 48 to the cam driver members 46 in turn pushing onto the movable die blocks 16. The movable die blocks 16 apply pressure to the side walls of the formed part. This provides sufficient contact pressure to achieve an acceptable heat transfer coefficient in turn allowing the entire part to transform into Martensite.

[0061] In one embodiment, the amount of travel of the movable die block may be in the range of about 0.2 to 0.5 mm. In one embodiment, the amount of travel of the movable die block 16 may be determined by the distance between upper and lower radius tangent.

[0062] In one embodiment, the formed component is hardened by cooling the portions thereof at a rate of cooling that is sufficiently rapid/fast to form a Martensitic structure in the formed component. Deformation and concomitant rapid cooling of the portions of the formed component within the die assemblies 12 and 14 produces the hot formed component, in which the austenite structure has been transformed into the Martensitic structure. For example, in one embodiment, the cooling rate of the formed component may be in the range of about 30°C/second to about 100°C/second. In one embodiment, the formed component in direction contact with the die surfaces is cooled from about 900°C to 200°C in about 7 to 8 seconds. In one embodiment, the cycle time for the hot formed member is about 7 to 8 seconds. In one embodiment, the hot formed member may be cooled by the die assemblies 12 and 14 prior to the ejection of the hot formed member from the die assemblies 12 and 14.

[0063] After the quenching procedure, the die assemblies 12 and 14 may be separated from one another (i.e., opened). That is, the stamping press then passes through its bottom dead center and returns on its upward stroke. The hot formed component may be removed from the die cavity 38. For example, the formed component is then pushed upwards from the bottom die assembly 14 and an operator or a robot then removes the finished component from the forming system 10 while it is in a relaxed state. In one embodiment, after being removed from the die assemblies 12 and 14, the member may be cooled to about room temperature, or at least to a temperature between about 20°C and about 250°C. In one embodiment, additional processing procedure(s) may be performed. These additional processing procedure(s) may include trimming, perforating, etc.

[0064] Figures 2 and 3 are schematic diagrams of a hot stamping/forming system 110 in accordance with another embodiment of the present patent application. The hot stamping/forming 110 includes a first die assembly 112 having a first die surface 124, a second die assembly 114 having a second die surface 132, and a movable die block 116 having a third die surface 136. The first die surface 124, the second die surface 132 and the third die surface 136 are configured to cooperate to form a die cavity 138 therebetween so as to receive a work piece 140 therein. Relative movement between the first die assembly 112 and the second die assembly 114 along a first axis A'-A' moves the die cavity 138 between an open position and a closed position. The die block 116 is movable relative to the first die assembly 112 in a direction transverse to the first axis A'-A', and the die block applies a force SF' on the work piece 40 that is predominantly transverse to forces F' applied to the work piece 140 by the first die assembly 112 and the second die assembly 114.

[0065] The system 110 also includes a cooling system 118 operatively associated with the first die assembly 112, the second die assembly 114 and the movable die block 116. In one embodiment, elements of the cooling system 118 may generally resemble and function in a manner similar to corresponding elements of the cooling system 18. Although not illustrated, the first die assembly 112, the second die assembly 114 and the movable die block 116 each include a cooling structure associated therewith so that the first die surface, the second die surface and the third die surface cool the work piece 140 in contact therewith when the die cavity 138 is closed.

[0066] This embodiment is similar to the embodiment previously described, except for the differences as will be noted below.

[0067] In one embodiment, the movable die block 116 includes a first movable die block portion 116a and a second movable die block portion 116b. The first movable die block portion 116a and the second movable die block portion 116b are configured to be axially aligned with each other when the die cavity 138 is in the closed position. That is, the first movable die block portion 116a and the second movable die block portion 116b are axially aligned with each other, when the die cavity 138 is in the closed position, such that a contact surface 139 of the first movable die block portion 116a engaged with a contact surface 141 of the second movable die block portion 116b. In one embodiment, the contact surfaces 139 and 141 of the first movable die block portion 116a and the second movable die block portion 116b are substantially planar surfaces.

[0068] In one embodiment, the first die body 122 includes an opening 123 to receive the first movable die block 116a. In one embodiment, the second die body 130 includes an opening 131 to receive the second movable die block 116b. In one embodiment, the openings 123 and 131 are axially aligned with each other when the die cavity 138 is in the closed position. In one embodiment, the first movable die block portion 116a and the second movable die block portion 116b are shaped and configured to slip fit into their corresponding openings 123 and 131, respectively.

[0069] In one embodiment, the forming system 110 includes a first gas cylinder spring 153 and a second gas cylinder spring 155. In one embodiment, elements of the first gas cylinder spring 153 and the second gas cylinder spring 155 may generally resemble and function in a manner similar to corresponding elements of the gas cylinder spring 48. In one embodiment, the first gas cylinder spring 153 is disposed in the first die assembly 112 and the second gas cylinder spring 155 is disposed in the second die assembly 114. In one embodiment, both the first gas cylinder spring 153 and the second gas cylinder spring 155 are operatively associated with the cam driver member 146. In one embodiment, the first gas cylinder spring 153 is larger than the second gas cylinder spring 155 and is configured to apply a relatively large force on the cam driver member 146 than that of the second gas cylinder spring 155. [0070] In one embodiment, the cam driver member 146 has a downwardly facing slanted cam surface 150 which is constructed and arranged to cooperate or engage with an upwardly facing slanted cam surface 152 of the second movable die block 116b.

[0071] In one embodiment, the forming system 10 includes an anti-rotation member 151 that is configured to prevent rotation of the second movable die block portion 116b. In one embodiment, the anti -rotation member 151 is disposed in the second die body and is configured to move together with the second movable die block portion 116b while preventing the second movable die block portion 116b from rotating with respect to the second die body 130. In one embodiment, the anti-rotation member 151 may include one or restraining portions that are protruding toward the second movable die block portion 116b for limiting the rotation of the second movable die block portion 116b. In illustrative embodiment, the anti-rotation member 151 is disposed on a top surface of the second movable die block portion 116b. In another embodiment, the anti -rotation member 151 may be disposed on a bottom surface or side surfaces of the second movable die block portion 116b.

[0072] In one embodiment, the forming system 110 may include a screw and spring arrangement 149 that is configured to both retain the movable die block 116 in the desired position to apply the force (by the third die surface) against the work piece 140. In one embodiment, the screw and spring arrangement 149 may be configured to retract the cam driver member 146 and the second movable die block 116b and, thus, the first movable die block(s) 116a from its force applying position.

[0073] In the illustrative embodiment, one movable die block 116 is shown on the right side of the forming system 110. However, it is contemplated that movable die block(s) may be positioned on the left side of the forming system 110. Also, the number of movable die blocks on each side (right side and left side) may vary. For example, in one embodiment, the forming system 110 may include a two movable die blocks per side configuration or a three movable die blocks per side configuration.

[0074] In one embodiment, the opening 123 of the first die body 122 is a through opening that enables the die surface 136 of the first movable die block portion 116a to contact or engage with the adjoining contact surface of the work piece 140 and the contact surface 139 of the first movable die block portion 116a to engage with the contact surface 141 of the second movable die block portion 1 16b. In one embodiment, the opening 131 of the second die body 130 is a through opening that enables the contact surface 139 of the first movable die block portion 116a to engage with the contact surface 141 of the second movable die block portion 116b and the downwardly facing slanted cam surface 150 of the cam driver member 146 to cooperate or engage with the upwardly facing slanted cam surface 152 of the second movable die block 116b.

[0075] The operation of the forming system 110 will now be described.

[0076] When the die cavity is the open position, the second nitrogen cylinder spring 155 applies pressure on the cam driver member 146 sliding it upwards towards its original position. That is, prior to the beginning of the next forming cycle, the second nitrogen cylinder spring 155 is energized to move the cam driver member 146 to its original position.

[0077] The forming procedure begins with the configuration in which the heated work piece 140 is placed upon the lower die body 130, when the die cavity is the open position. After the work piece 140 is mounted on the lower die body 130, the upper die assembly 112 is lowered (to its die position) by the stamping press or ram until a downwardly facing, lower clamping surface of the upper die assembly 112 engages an upwardly facing surface of the sheet metal blank 140 such that the work piece 140 is sandwiched between the die surface 124 of the upper die body 122, the die surface 136 of the movable die block 116a and the die surface 132 of the lower die body 130.

[0078] When the die cavity is in the closed position, the contact surface 139 of the first movable die block portion 116a is axially aligned with and engages the contact surface 141 of the second movable die block portion 116b. When the die cavity is in the closed position, the gas cylinder spring 153 operates to apply a force on the cam driver member 146. In one embodiment, the gas cylinder spring 153 operates to apply the downward force on a top surface 147 of the cam driver member 146. The force applied by the gas cylinder spring 153 on the top surface 147 of the cam driver member 146 causes the cam driver member 146 to move in a downwardly direction. In one embodiment, the movement of the cam driver member 146 is a linear longitudinal downwardly movement. In one embodiment, the movement of the cam driver member 146 is a vertical movement. In one embodiment, the movement of the cam driver member 146 is in a direction as shown by an arrow DF.

[0079] As the cam driver member 146 moves in the downwardly direction, the downwardly facing slanted cam surface 150 of the cam driver member 146 cams or wedges against the upwardly facing slanted cam surface 152 of the second movable die block portion 116b causing the second movable die block portion 116b to move inwardly towards the center of the forming system 110. That is, as the cam driver member 146 moves in the downwardly direction, the downwardly facing slanted cam surface 150 of the cam driver member 146 slidingly engages and bears against the upwardly facing slanted cam surface 152 of the second movable die block portion 116b thereby advancing the second movable die block portion 116b in a direction transverse to the axial downwardly direction of the movement of the cam driver member 146.

[0080] In one embodiment, the movement of the second movable die block portion 116b is a transverse or lateral movement (towards the center of the forming system 110). In another embodiment, the movement of the second movable die block portion 116b is a linear transverse or lateral movement (towards the center of the forming system 110). The inwardly movement of the second movable die block portion 116b in turn forces the first movable die block portion 116a against the lower die body 130 creating pressure against the work piece 140 received in the die cavity. That is, the transverse or lateral movement of the second movable die block portion 116b exerts a (compressive) force on the first movable die block portion 116a to drive the first movable die block portion 116a in a direction transverse to the axis A'-A' . For example, as the second movable die block portion 116b moves in the transverse or lateral direction, the contact surface 141 of the second movable die block portion 116b engages with and applies a force on the contact surface 139 of the first movable die block portion 116a advancing the first movable die block portion 116a in a direction transverse to the axis A'-A' . The transverse movement of the first movable die block portion 116a exerts a force on the work piece received in the die cavity. In one embodiment, the movable die block 116a is configured to apply pressure to the side walls of the work piece received in the die cavity (or the formed part). In one embodiment, the movement of the first movable die block portion 116a and the second movable die block portion 116b are transverse movements in a direction transverse to the axis A'-A', while the movement of the cam driver member 146 is an axial longitudinal, vertical movement in a direction parallel to or along with the axis A'-A' . ). In one embodiment, the movement of the first movable die block portion 116a and the second movable die block portion 116b are in the direction of an arrow S.

[0081] Thus, the downward axial force from the cam driver member 146 is translated into a sideward or laterally applied force on the work piece 140 by the die block 116a. The arrangement of the cam driver member 146 and the movable die blocks 116a and 116b are configured to convert the axial or longitudinal movement of the cam driver member 146 into a lateral or transverse movement of translation (of the movable die blocks 116a and 116b) so as to apply a transverse force on the work piece 140 received in the die cavity. In one embodiment, the force may be translated from downward (on the cam driver member 146) to sideways (of the die block 116a on the side walls of the work piece 140) by about 90 degree. In another embodiment, the force may be translated from downwards to sideways by about 30 to 150 degree. In another embodiment, the force may be translated from downwards to sideways by about 60 to 120 degree.

[0082] The cam driver member 146 is configured to urge the die surface 136 of the first movable die block portion 116a tightly against its adjoining contact surface of the work piece 140 so as to increase the area of contact between the first movable die block portion 116a and the work piece 140, and provide an improved heat transfer path between the work piece 140 and the movable die block portion 116a.

[0083] The camming action has effected displacement of the second movable die block portion 116b and the first movable die block portion 116a so as to impose maximum contact pressure between the work piece 140 and the movable die block portion 116a. In one embodiment, increased force applied by the third die surface 136 against the work piece 140 increases thermal transfer between the third die surface 136 and the work piece 140. The movable die blocks 116 apply pressure to the side walls of the formed part. This provides sufficient contact pressure to achieve an acceptable heat transfer coefficient in turn allowing the entire part to transform into Martensite.

[0084] In the illustrative embodiment of Figure 1, the gas cylinder spring applies a transverse force on the cam driver member to effect displacement of the movable die block 16, while in the embodiments of Figures 2 and 3, the gas cylinder spring applies a longitudinal force on the cam driver member to effect displacement of the second movable die block portion 116b and the first movable die block portion 116a. However, in both these embodiments, the movable die block applies a force to the work piece that is predominantly transverse to forces applied to the work piece by the first die assembly and the second die assembly.

[0085] Figures 4 and 5 are schematic diagrams of a hot stamping/forming system 410 in accordance with another embodiment of the present patent application. The hot stamping/forming 410 includes a first die assembly 412 having a first die surface 424, a second die assembly 414 having a second die surface 432, and a movable die block 416 having a third die surface 436. The first die surface 424, the second die surface 432 and the third die surface 436 are configured to cooperate to form a die cavity 438 therebetween so as to receive a work piece 440 therein. Relative movement between the first die assembly 412 and the second die assembly 414 along a first axis A"- A" moves the die cavity 438 between an open position and a closed position. The die block 416 is movable relative to the first die assembly 412 in a direction transverse to the first axis A"- A", and the die block applies a force SF" on the work piece 440 that is predominantly transverse to forces F' applied to the work piece 440 by the first die assembly 412 and the second die assembly 414.

[0086] The system 410 also includes a cooling system 418 operatively associated with the first die assembly 412, the second die assembly 414 and the movable die block 416. In one embodiment, elements of the cooling system 418 may generally resemble and function in a manner similar to corresponding elements of the cooling system 18. Although not illustrated, the first die assembly 412, the second die assembly 414 and the movable die block 416 each include cooling structures or channels associated therewith so that the first die surface, the second die surface and the third die surface cool the work piece 440 in contact therewith when the die cavity 438 is closed.

[0087] This embodiment is similar to the embodiments previously described, except for the differences as will be noted below.

[0088] In one embodiment, the first die body 422 includes an opening 423 to receive the movable die block 416 and the cam driver member 446. In one embodiment, the opening 423 has a L-shaped configuration.

[0089] In one embodiment, the forming system 410 includes a gas cylinder spring 448 that is configured to apply an upwardly force on the cam driver member 446 when the die cavity is in the closed position. In one embodiment, elements of the gas cylinder spring 448 may generally resemble and function in a manner similar to corresponding elements of the gas cylinder spring 48.

[0090] In one embodiment, the cam driver member 446 has an upwardly downwardly facing slanted cam surface 450 which is constructed and arranged to cooperate or engage with a downwardly facing slanted cam surface 452 of the movable die block 416.

[0091] In one embodiment, the forming system 410 may include a screw and spring arrangement 449 that is configured to both retain the movable die block 416 in the desired position to apply the force (by the third die surface) against the work piece 440. In one embodiment, the screw and spring arrangement 449 may be configured to retract the cam driver member 446 and, thus, the movable die block 416 from its force applying position.

[0092] In the illustrative embodiment, one movable die block 416 is shown on each side (the right side and the left side) of the forming system 410. However, the number of movable die blocks on each side may vary. For example, in one embodiment, the forming system 410 may include a two movable die blocks per side configuration or a three movable die blocks per side configuration.

[0093] In one embodiment, the opening 423 of the first die body 422 is a through opening that enables the die surface 436 of the movable die block 416 to contact or engage with the adjoining contact surface of the work piece 440.

[0094] The operation of the forming system 410 will now be described.

[0095] The forming procedure begins with the configuration in which the heated work piece 440 is placed upon the lower die body 430, when the die cavity is the open position. After the work piece 440 is mounted on the lower die body 430, the upper die assembly 412 is lowered (to its die position) by the stamping press or ram until a downwardly facing, lower clamping surface of the upper die assembly 412 engages an upwardly facing surface of the sheet metal blank 440 such that the work piece 440 is sandwiched between the die surface 424 of the upper die body 422, the die surface 436 of the movable die block 416 and the die surface 432 of the lower die body 430.

[0096] When the die cavity is in the closed position, as shown in Figure 5, the gas cylinder spring 448 operates to apply a force on the cam driver member 446. In one embodiment, the gas cylinder spring 448 operates to apply the upwardly force on a bottom surface 447 of the cam driver member 446. The force applied by the gas cylinder spring 448 on the bottom surface 447 of the cam driver member 446 causes the cam driver member 446 to move in an upwardly direction. In one embodiment, the movement of the cam driver member 446 is in a linear longitudinal upwardly movement.

[0097] As the cam driver member 446 moves in the upwardly direction, the upwardly facing slanted cam surface 450 of the cam driver member 446 cams or wedges against the downwardly facing slanted cam surface 452 of the movable die block 416 causing the movable die block 416 to move inwardly towards the center of the forming system 410. That is, the upwardly movement of the cam driver member 446 forces the movable die block 416 against the lower die body 430 creating pressure against the work piece 440. In one embodiment, the movement of the movable die block 416 is a linear transverse movement (towards the center of the forming system 110).

[0098] The cam driver member 446 is configured to urge the die surface 436 of the movable die block 416 tightly against its adjoining contact surface of the work piece 440 so as to increase the area of contact between the movable die block 416 and the work piece 440, and provide an improved heat transfer path between the work piece 440 and the movable die block 416. The camming action has effected displacement of the movable die block portion 416 so as to impose maximum contact pressure between the work piece 440 and the movable die block 416. In one embodiment, increased force applied by the third die surface 436 against the work piece 440 increases thermal transfer between the third die surface 436 and the work piece 440. The movable die blocks 416 apply pressure to the side walls of the formed part. This provides sufficient contact pressure to achieve an acceptable heat transfer coefficient in turn allowing the entire part to transform into Martensite.

[0099] In one embodiment, the hot formed member is a vehicle body member or vehicle body assembly. In one embodiment, the vehicle body component that is formed or produced by the system of the present application may include external body panel members, vehicle body pillars (e.g., A-pillars, B-pillars, etc.), vehicle side impact protection members, vehicle sill members, vehicle frame components, vehicle bumper beams, vehicle bumper mounts, vehicle door pillar reinforcement members, vehicle roof frame members, vehicle roof panel members, vehicle roof rails, vehicle rear end cross members, vehicle rocker members, vehicle door intrusion beams and vehicle front end cross members.

[00100] In one embodiment, the forming system may include a blank or work piece holder, which is mechanism configured to prevent the blank or work piece from moving during the forming procedure and/or quenching procedure. In another embodiment, the blank or work piece holder may be optional.

[00101] In one embodiment, the forming system may include a pair of ejection structures (not shown), which are disposed within the lower die body. The ejection structures may be configured to eject the hot formed component (i.e., in the event it is form fitted to the die surfaces of the lower die assembly) after the forming procedure. In another embodiment, the ejection structures may be optional. [00102] In one embodiment, the hot formed component may be held inside the forming system during the cooling or quenching procedure so as to maintain the desired shape of the hot formed component while it is being cooled and/or hardened. In one embodiment, a fixture may be used to maintain the dimensions of the hot formed component during the cooling procedure. In another embodiment, the fixture may be optional.

[00103] Construction of the forming system in accordance with the teachings of the present application permits the rate of quenching at each point on the die surface to be controlled in a precise manner. This is particularly advantageous for high-volume production as it is possible to employ relatively short overall cycle times while achieving an Austenite-to-Martensite transformation.

[00104] In one embodiment, the hot formed member may be referred to as a hot stamped member or a hot shaped member. For example, the hot stamping allows for the forming of complex part geometries with the final product achieving ultra high strength material properties.

[00105] Although the present patent application has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that the present patent application is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. In addition, it is to be understood that the present patent application contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims

What is claimed is:

1. A forming system comprising:

a first die assembly having a first die surface;

a second die assembly having a second die surface;

a movable die block having a third die surface; and

a cooling system operatively associated with the first die assembly, the second die assembly and the movable die block,

wherein the first die surface, the second die surface and the third die surface are configured to cooperate to form a die cavity therebetween so as to receive a work piece therein, wherein relative movement between the first die assembly and the second die assembly along a first axis moves the die cavity between an open position and a closed position,

wherein the die block is movable relative to the first die assembly in a direction transverse to the first axis, and

wherein the die block applies a force to the work piece that is predominantly transverse to forces applied to the work piece by the first die assembly and the second die assembly.

2. The forming system of claim 1, wherein the die block applies the force to the work piece that is perpendicular to the forces applied to the work piece by the first die assembly and the second die assembly.

3. The forming system of claim 1, wherein, in the closed position, the first and second die surfaces apply the forces to the work piece in a direction generally corresponding to the first axis.

4. The forming system of claim 1, wherein increased force applied by the third die surface against the work piece increases thermal transfer between the third die surface and the work piece.

5. The forming system of claim 1, wherein the first die assembly, the second die assembly and the movable die block having a cooling structure associated therewith so that the first die surface, the second die surface and the third die surface cool the work piece in contact therewith when the die cavity is closed.

6. The forming system of claim 1, further comprising a biasing device that is configured to enable the movement of the die block relative to the first die assembly.

7. The forming system of claim 6, wherein the biasing device is a gas cylinder spring.

8. The forming system of claim 7, wherein the gas cylinder spring is a nitrogen cylinder spring.

9. The forming system of claim 6, further comprising a cam driver member that is configured to be operatively connected to the biasing device, wherein the biasing device and the cam driver member are configured to enable the movement of the die block relative to the first die assembly.

10. The forming system of claim 9, wherein the cam driver member and the movable die block have cam surfaces that are configured to engage with each other to enable the movement of the die block relative to the first die assembly.

11. The forming system of claim 10, wherein the cam driver member and the movable die block are configured to translate a downward axial force of the cam driver member into a lateral or side applied force on the work piece by the movable die block.

12. The forming system of claim 10, wherein the cam driver member and the movable die block are configured to translate a downward axial force of the movable die block into a lateral or side applied force on the work piece by the movable die block.

13. The forming system of claim 11, wherein the force is translated from the downward axial force to the lateral or side applied force by 90 degrees.

14. The forming system of claim 1, wherein the die cavity is configured to have a shape that corresponds to a final shape of the work piece after a hot forming procedure.

15. The forming system of claim 1, wherein the cooling system includes cooling channels formed in the die block, wherein the cooling channels are constructed and arranged to carry a cooling fluid.

16. The forming system of claim 15, wherein the cooling system includes a pressure source for forcing the cooling fluid through the cooling channels.

17. The forming system of claim 1, wherein the first die assembly is an upper die assembly.

18. A method of forming a sheet metal member in a forming system comprising a first die assembly having a first die surface, a second die assembly having a second die surface, a movable die block having a third die surface, and a cooling system operatively associated with the first die assembly, the second die assembly and the movable die block, wherein the first die surface, the second die surface and the third die surface are configured to cooperate to form a die cavity therebetween so as to receive a work piece therein, the method comprising:

moving the first die assembly relative to the second die assembly along a first axis to move the die cavity from an open position to a closed position,

moving the die block relative to the first die assembly in a direction transverse to the first axis, and

applying a force to the work piece with the die block that is predominantly transverse to forces applied to the work piece by the first die assembly and the second die assembly.

19. The method of claim 18, wherein the force applied to the work piece by the die block is perpendicular to the forces applied to the work piece by the first die assembly and the second die assembly.

20. The method of claim 18, wherein the forces applied to the work piece by the first die assembly and the second die assembly are in a direction generally corresponding to the first axis.

21. The method of claim 18, wherein increased force applied by the third die surface against the work piece increases thermal transfer between the third die surface and the work piece.

22. The method of claim 18, wherein the first die surface, the second die surface and the third die surface are configured to cool the work piece in contact therewith when the die cavity is closed.

23. The method of claim 18, wherein the first die assembly is an upper die assembly.