Patent ID: 6928848

Claim:
A method of forming a hem flange for securing a sheet metal outer panel to an inner panel, comprising: retaining a sheet metal blank on a first die with a peripheral portion of the sheet metal blank initially extending outboard of a first flange forming portion, the first flange forming portion having a first supporting portion, a first flange pre-forming surface, and a first radiused portion; moving a first bender in a direction normal to the sheet metal blank surface and into engagement with the peripheral portion of the sheet metal blank and bending the peripheral portion over the first radiused portion and against the flange pre-forming surface to form a sheet metal blank with a partially formed flange; securing the sheet metal blank having a partially formed flange to a second die with the partially formed flange of the sheet metal blank initially extending outboard of a second flange forming portion, the second flange forming portion having a second supporting portion, a second flange forming surface and a second radiused portion, the second radiused portion being less than the first radius; moving a second bender into engagement with the partially formed flange to form the partially formed flange against the second flange forming surface and around the second radiused portion by moving the second bender at an angle relative to the sheet metal blank surface that is at least partially directed toward the second flange forming surface.