Method and die set for forming a surface in a metal panel

A method of forming a class “A” finish surface in a panel blank, the method comprising:

• positioning the panel blank between a stationary die and a moveable die of a die set;
• moving the moveable die toward the stationary die to deform the panel blank therebetween;
• maintaining positive stresses in the panel blank in the region of the panel blank that will form the surface, as the moveable die moves toward the stationary die;
• and
• continuing to move the moveable die toward the stationary die, while maintaining positive stresses in the panel blank in the region of the panel blank that will form the surface, to further deform the panel blank into a formed shape that includes the class “A” finish surface.

A die set for forming a panel having a surface, the die set comprising:

• a stationary die and an opposing moveable die disposed opposite the stationary die, wherein the moveable die is operable to move toward and away from the stationary die;
• a clamp attached to the stationary die and operable to secure a panel blank to the stationary die;
• wherein the moveable die includes a moveable brazing formation surface and the stationary die includes a stationary brazing formation surface opposing the moveable brazing formation surface for forming a surface in the panel blank therebetween;
• wherein one of the moveable die and the stationary die includes a male bead forming portion, and the other of the moveable die and the stationary die includes a female bead forming portion disposed opposite the male bead forming portion for forming a bead in the panel blank therebetween;
• wherein the male bead forming portion and the female bead forming portion extend in a continuous and uninterrupted, generally parallel relationship with the moveable brazing formation surface and the stationary brazing formation surface;
• wherein the male bead forming portion and the female bead forming portion are disposed opposite the clamp and across the moveable brazing formation surface and the stationary brazing formation surface from the clamp;
• and
• wherein the male bead forming portion and the female bead forming portion are operable to engage the panel blank during initial movement of the moveable die toward the stationary die to induce tensile forces in both a first direction parallel to a path of the surface and a second direction transverse to the path of the surface.