Two die process

Abstract

A closure panel forming and assembly process includes inputting partially stamped inner and outer panels into the assembly system and finished assemblies out. The invention is a manufacturing process for closure panel assemblies, doors, deck lids, hoods, liftgates and other similar panels. The process has a reduced stamping operation of only two die stages, with the first operation being a draw operation followed by a second operation of trim and pierce. These operations may be done at a satellite location which may be within the same facility or at an outside location. All additional metal forming operations are done at an assembly system.

1 . A split site forming and assembly process including the steps of:
 conducting first and second forming steps on panels at a forming site using two dies in at least one press, and loading the partially formed panels onto a dunnage rack, wherein no flanging of the panels is performed at the forming site;   transporting the dunnage rack with the partially formed panels from the forming site to an assembly site; and   loading the partially formed panels from the dunnage rack into a continuing forming and assembly operation at the assembly site.   
   
   
       2 . The process of  claim 1  wherein the first and second forming steps are conducted with at least one forming press and two dies. 
   
   
       3 . The process of  claim 2  wherein the first and second forming steps are conducted with first and second forming presses and a separate forming die in each press. 
   
   
       4 . The process of  claim 3  wherein the first and second forming steps are conducted serially in the first and second presses. 
   
   
       5 . The process of  claim 2  wherein the first and second forming steps are conducted in batches in a single press with die change out between the batches. 
   
   
       6 . The process of  claim 2  wherein the first and second forming steps include a drawing step and a trim and pierce step. 
   
   
       7 . The process of  claim 1  including further forming and assembly steps performed at the assembly site. 
   
   
       8 . The process of  claim 6  including further forming and assembly steps performed at the assembly site. 
   
   
       9 . The process of  claim 8  wherein the further forming and assembly steps include flanging and assembly steps. 
   
   
       10 . The process of  claim 9  including a trim step prior to the flanging step and an inspection step subsequent to the assembly step. 
   
   
       11 . A split site forming and assembly process for forming closure panel assemblies, the process including:
 conducting first and second forming steps on outer panels with two dies in at least one press at a forming site and loading the partially formed outer panels onto a dunnage rack, wherein no flanging of the panels is performed at the forming site;   transporting the dunnage rack with the partially formed outer panels from the forming site to an assembly site;   loading the partially formed outer panels from the dunnage rack into a continuing forming and assembly operation at the assembly site;   conducting additional forming steps including flanging of the outer panels at the assembly site; and   conducting assembly steps including hemming of the outer panels to mating inner panels and fixing the outer and inner panels together to form closure assemblies.   
   
   
       12 . The process of  claim 11  including a trim step prior to the flanging step and an inspection step subsequent to the assembly step. 
   
   
       13 . The process of  claim 11  wherein the first and second forming steps are conducted with at least one forming press and two dies. 
   
   
       14 . The process of  claim 13  wherein the first and second forming steps are conducted with first and second forming presses and a separate forming die in each press. 
   
   
       15 . The process of  claim 14  wherein the first and second forming steps are conducted serially in the first and second presses. 
   
   
       16 . The process of  claim 11  wherein the first and second forming steps are conducted in batches in a single press with die change out between the batches. 
   
   
       17 . The process of  claim 13  wherein the first and second forming steps include a drawing step and a trim and pierce step.