Hot stamping system and method

Abstract

A method and system for hot stamping components. The method includes forming at least one weld nugget on at least on blank. The method also includes forming at least one pocket in at least one die segment of a die. The method also includes positioning the blank in alignment with the at least one die segment with the at least one weld nugget aligned with the at least one pocket. The method also includes stamping the at least one blank with the at least one die segment, with the at least one weld nugget received in the at least one pocket of the at least one die segment

What is claimed is: 
     
         1 . A method for hot stamping components, comprising:
 forming at least one weld nugget on at least one blank;   forming at least one pocket in at least one die segment of a die;   positioning the blank in alignment with the at least one die segment with the at least one weld nugget aligned with the at least one pocket; and   stamping the at least one blank with the at least one die segment, with the at least one weld nugget received in the at least one pocket of the at least one die segment.   
     
     
         2 . The method as set forth in  claim 1 , wherein the at least one weld nugget is substantially the same size as the at least one pocket. 
     
     
         3 . The method as set forth in  claim 2 , wherein the at least one weld nugget has a height, the at least one pocket has a depth, and wherein the height of the at least one weld nugget is at least a size of the depth of the at least one pocket. 
     
     
         4 . The method as set forth in  claim 3 , wherein the height of the at least one weld nugget is in the range of approximately 0.25 to 0.50 mm, and wherein the depth of the at least one pocket is in the range of approximately 0.25 to 0.50 mm deep. 
     
     
         5 . The method as set forth in  claim 2 , wherein the at least one weld nugget has a width, wherein the at least one pocket has a width, and wherein the width of the at least one weld pocket is at least a size of the width of the at least one weld nugget. 
     
     
         6 . The method as set forth in  claim 5 , wherein the at least one weld nugget has a diameter in the range of approximately 7 to 15 mm, and wherein the at least one pocket has a diameter in the range of approximately 7 to 15 mm. 
     
     
         7 . The method as set forth in  claim 1 , wherein the at least one die segment includes a first die segment and a second die segment overlying one another, and wherein the at least one blank is positioned between the first and second die segments. 
     
     
         8 . The method as set forth in  claim 7 , wherein the at least one blank has a first side facing the first die segment and a second side facing the second die segment, wherein the at least one spot weld includes at least one first spot weld on the first side of the blank and at least one second spot weld on the second side of the blank, wherein the first die segment has at least one first pocket aligned with the at least one first spot weld for receiving the at least one first spot weld, and wherein the second die segment has at least one second pocket aligned with the at least one second spot weld for receiving the at least one second spot weld. 
     
     
         9 . The method as set forth in  claim 8 , wherein the at least one first spot weld includes a plurality of first spot welds on the first side of the blank, the at least one second spot weld includes a plurality of second spot welds on the second side of the blank, wherein the at least one first pocket includes a plurality of first pockets defined by the first die segment each for receiving one of the plurality of first spot welds, and wherein the at least one second pocket includes a plurality of second pockets defined by the second die segment each for receiving one of the plurality of second spot welds. 
     
     
         10 . The method as set forth in  claim 1 , further including determining a location of the at least one pocket on the at least one die based on computer aided design data, and wherein forming the at least one pocket includes milling the at least one pocket into the at least one die at the determined location of the at least one pocket. 
     
     
         11 . The method as set forth in  claim 1 , further including determining a location of the at least one weld nugget on the at least one blank based on computer aided design data, and wherein forming the at least one weld nugget includes spot welding the at least one weld nugget at the determined location of the at least one weld nugget. 
     
     
         12 . The method as set forth in  claim 1 , wherein the at least one blank is made of a 22MnB5 boron steel. 
     
     
         13 . The method as set forth in  claim 1 , further including heating the at least one blank in a furnace prior to stamping the at least one blank in the die. 
     
     
         14 . The method as set forth in  claim 13 , wherein the at least one blank is heated to a temperature that exceeds 900 degrees Fahrenheit during the step of heating the at least one blank in the furnace. 
     
     
         15 . The method as set forth in  claim 1 , further including cold forming the at least one blank prior to stamping the at least one blank. 
     
     
         16 . The method as set forth in  claim 1 , further including quenching the at least one blank after stamping. 
     
     
         17 . A system for hot stamping components, comprising:
 at least one die segment;   a blank for being positioned in alignment with the at least one die segment and for undergoing a stamping operation via engagement with the at least one die segment;   the blank presenting at least one weld nugget; and   the at least one die defining at least one pocket in alignment with the at least one weld nugget of the at least one blank such that the at least one weld nugget is received by the at least one pocket during stamping of the blank with the at least one die segment.   
     
     
         18 . The system as set forth in  claim 17 , wherein the at least one weld nugget has a height, the at least one pocket has a depth, and wherein the depth of the at least one pocket is at least the height of the at least one weld nugget. 
     
     
         19 . The system as set forth in  claim 18 , wherein the height of the at least one weld nugget is between approximately 0.25 to 0.50 mm deep, and wherein the depth of the at least one pocket is between approximately 0.25 to 0.50 mm deep. 
     
     
         20 . The system as set forth in  claim 17 , wherein the at least one weld nugget has a width, wherein the at least one pocket has a width, and wherein the width of the at least one pocket is at least as large as the width of the at least one weld nugget.