Patent ID: 6532786
Filing Date: 2003-03-18
Classification: B21D

Abstract:
A method for forming a sheet of plastically deformable material from an initial substantially flat shape into a defined contoured shape having a first contoured surface definition and an opposite corresponding second contoured surface definition that is substantially evenly spaced from the first surface definition by the thickness of the sheet of plastically deformable material when formed, the method for forming the sheet of plastically deformable material comprising the following steps:(a) fashioning a forming die having a forming surface that substantially matches the first contoured surface definition, (b) holding the sheet of plastically deformable material in a fixed relationship with surface of the forming die so that the sheet of material contacts the forming die at a tangent area, (c) defining a forming path that traces the second contoured surface definition, (d) orienting the forming path in relation with the surface of the forming die so that the position of the forming path in relation to the surface of the forming die substantially corresponds to the relative position of the second surface definition in relation to the first surface definition, (e) providing a forming tool having a contact surface for making contact with a small area, (f) holding the forming die stationary, and, (g) moving the forming tool in relation to the stationary forming die and the sheet of plastically deformable material, such that the contact surface of the forming tool moves along the forming path, the contact surface of the forming tool coming into contact with the plastically defomable sheet of material as it moves along the forming path, the forming tool deforming the sheet of plastically deformable material so as to at least substantially conform it to the surface of the stationary forming die, the sheet of plastically deformable material thereby formed into a shape that substantially conforms to the defined shape when the contact surface of the forming tool has completely moved along the forming path.