Flat top metal gainer

Abstract

A method of forming a metal part that includes placing a metal blank in a stamping apparatus having a first die including a plurality of metal gainers and a second die including a plurality of recesses that correspond to the plurality of metal gainers, and compressing the metal blank such that the metal gainers and the corresponding recesses provide the metal blank with regions of localized stretching. Each of the metal gainers and recesses includes a flat surface such that during the compressing of the metal blank to provide the metal blank with the regions of localized stretching, a strain exerted on the metal blank by the metal gainers and recesses is less than a strain exerted on the metal blank by metal gainers and recesses that do not include the flat surface.

1 . A method of forming a metal part, comprising:
 placing a metal blank in a stamping apparatus having a first die including a plurality of metal gainers and a second die including a plurality of recesses that correspond to the plurality of metal gainers, and forming the metal blank such that the metal gainers and the corresponding recesses provide the metal blank with regions of localized stretching, the regions of localized stretching being located along a trim line of the metal blank that corresponds to a region of the metal blank that will be trimmed from the metal blank;   after providing the metal blank with the regions of localized stretching, trimming the metal blank along the trim line such that portions of regions of localized stretching remain along the trim line; and   after trimming the metal blank along the trim line, subjecting the metal blank including the regions of localized stretching to a stretch-flanging process that forms a flange at the trim line;   wherein each of the metal gainers and recesses includes a flat surface surrounded by a side surface such that during the forming of the metal blank to provide the metal blank with the regions of localized stretching, a combined strain exerted on the metal blank by the metal gainers and recesses that include the flat surface in combination with the stretch-flanging process is less than a stretch limit of a material of the metal blank.   
     
     
         2 . The method according to  claim 1 , wherein a surface area of the flat surfaces of the metal gainers and the recesses ranges between 40% to 90% of a total surface area of the metal gainers and the recesses. 
     
     
         3 . The method according to  claim 1 , wherein the metal gainers and recesses are at least one of oval-shaped, triangular-shaped, diamond- or square-shaped, or round. 
     
     
         4 . The method according to  claim 3 , wherein a shape of the flat surface of each of the metal gainers and recesses is the same as an overall shape of the metal gainer and recess. 
     
     
         5 . The method according to  claim 3 , wherein a shape of the flat surface of each of the metal gainers and recesses is different from an overall shape of the metal gainer and recess. 
     
     
         6 . The method according to  claim 1 , wherein the metal blank is formed of an advanced high strength metal. 
     
     
         7 . A method of forming a metal part, comprising:
 placing a metal blank in a stamping apparatus having a first die including a plurality of metal gainers and a second die including a plurality of recesses that correspond to the plurality of metal gainers, and forming the metal blank such that the metal gainers and the corresponding recesses provide the metal blank with regions of localized stretching, the regions of localized stretching being located along a trim line of the metal blank that corresponds to a region of the metal blank that will be trimmed from the metal blank;   after providing the metal blank with the regions of localized stretching, trimming the metal blank along the trim line such that portions of regions of localized stretching remain along the trim line; and   after trimming the metal blank along the trim line, subjecting the metal blank including the regions of localized stretching to a stretch-flanging process that forms a flange at the trim line;   wherein each of the metal gainers and recesses includes a flat surface surrounded by a side surface such that during the forming of the metal blank to provide the metal blank with the regions of localized stretching.   
     
     
         8 .- 9 . (canceled) 
     
     
         10 . The method according to  claim 7 , wherein a surface area of the flat surfaces of the metal gainers and the recesses ranges between 40% to 90% of a total surface area of the metal gainers and the recesses. 
     
     
         11 . The method according to  claim 7 , wherein the metal gainers and recesses are at least one of oval-shaped, triangular-shaped, diamond- or square-shaped, or round. 
     
     
         12 . The method according to  claim 11 , wherein a shape of the flat surface of each of the metal gainers and recesses is the same as an overall shape of the metal gainer and recess. 
     
     
         13 . The method according to  claim 11 , wherein a shape of the flat surface of each of the metal gainers and recesses is different from an overall shape of the metal gainer and recess. 
     
     
         14 . The method according to  claim 7 , wherein the metal blank is formed of an advanced high strength metal. 
     
     
         15 . A stamping press comprising:
 a first die including a plurality of protrusions; and   a second die including a plurality of recesses that correspond to the plurality of protrusions,   wherein the plurality of protrusions in combination with the plurality of protrusions are configured to provide a metal blank with regions of localized stretching when the metal blank is formed between the plurality of protrusions and the plurality of recesses, and   wherein each of the protrusions and each of the recesses includes a flat surface surrounded by a side surface such that during the forming of the metal blank to provide the metal blank with the regions of localized stretching; and   wherein a shape of the flat surface of each of the protrusions and recesses is the same as an overall shape of the protrusions and recesses.   
     
     
         16 . The stamping press according to  claim 15 , wherein a surface area of the flat surfaces of the protrusions and the recesses ranges between 40% to 90% of a total surface area of the protrusions and the recesses. 
     
     
         17 . The stamping press according to  claim 15 , wherein the protrusions and recesses are at least one of oval-shaped, triangular-shaped, diamond-or square-shaped, or round. 
     
     
         18 .- 19 . (canceled)