In-process measurement of springback in tube rotary draw bending

Simonetto, Enrico; Ghiotti, Andrea; Bruschi, Stefania

doi:10.1007/s00170-020-06453-w

Cited by 19 publications

(8 citation statements)

References 31 publications

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“…No visible wrinkles are observed on all three samples. Considering the intrinsic problem of spring back associated with every RDB process [37], a precise repeatability is exhibited by the experiments.…”

Section: Resultsmentioning

confidence: 99%

“…He demonstrated that reduced contact surfaces of a bend die provide appropriate bending results in a RDB process under some speci c considerations. The pressure die is one of the fundamental forming tools used in a RDB process since it provides a counter support to the bent tube during bending process [11]. Borchmann et al demonstrated that pressure die clearance is a signi cant process parameter in RDB processes [12].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Additive Manufacturing of Polymeric Pressure Die For Rotary Draw Bending Process

Kaleem,

Steinheimer,

Frohn-Sörensen

et al. 2024

Preprint

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Additive manufacturing (AM) possess enormous potential to benefit the manufacturing industry. Presently, Rotary Draw Bending (RDB) is one of the most commonly used industrial process for bending metal tubes. RDB processes are carried out by using customized forming tools which are manufactured according to the shape and size of the tube. This research encompasses design and development of a pressure die by Fused Deposition Modelling (FDM) technique. In this research paper, the additively manufactured pressure die is named as ‘AM-pressure die’. The material used to fabricate the AM-pressure die is a thermoplastic polymer (ecoPLA). The mechanical properties of ecoPLA are studied in relation to the process conditions of a RDB process. Feasibility of using AM-pressure die in a RDB process is conducted by stress analysis using Finite Element (FE) simulation in the software ‘Autodesk Inventor’. The design model is imported in tube solver environment of the software ‘PAMSTAMP’ and a complete RDB process is simulated. The AM-pressure die is practically fabricated by FDM 3D printer and experimentally tested on a RDB machine. Practical experiments verify the simulation results. The advantages accrued by using AM-pressure die in a RDB process are discussed. This is an application oriented research intended to widen the avenue of using cost effective and individualized forming tools in RDB processes.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Polymeric Pressure Die For Rotary Draw Bending Process

Kaleem,

Steinheimer,

Frohn-Sörensen

et al. 2024

Preprint

View full text Add to dashboard Cite

show abstract

“…Allwood et al [4] discuss digital cameras, laser sensors and light section sensors as optical measurement systems for the bending angle for the case of V-bending. Simonetto [5] investigated the springback in rotary draw bending and proposed an inline inertial measuring unit system (IMU) enabling a closed-loop control for the process. In another contribution the author proves the strategy also for the three-roll-push-bending [6].…”

Section: State Of the Artmentioning

confidence: 99%

Inline Monitoring of the Geometry of Free-form Bent Components

Scandola,

Maier,

Meier

et al. 2024

IOP Conf. Ser.: Mater. Sci. Eng.

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The free-form bending process shows a high potential for the manufacturing of bent structural components. Especially in the automotive sector, the process can be employed for the production of arbitrary geometries evolving in the 3D-space, reducing tooling costs and production times. In addition, it is characterised by an outstanding flexibility, and allows the manufacturing of variants of a single component just with the adaption of the tool kinematics. Nevertheless, the reproducibility of the process is a challenging task, and a process monitoring approach is required. In this contribution, an inline-measurement strategy for evaluating the resulting geometry of free-form bent parts is developed. First, a review of the actual measurement system is given. Successively, the inline measurement of the bending radius using a laser displacement sensor, as well as of the bending angle by means of an IR-camera are presented. The obtained inline signals are then processed to retrieve the geometry of the obtained part, and the strategy is validated by comparison with the offline measurement results. The developed inline-system represents the first step towards the development and the monitoring of the free-form bending process.

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“…Current measurement methods are mainly divided into two categories: contact measurement and non-contact measurement. Contact measurement methods include the modeling method [4], coordinate measuring machine (CMM) measurement method [5], etc. Since the modeling method requires a comparison device for each tube to be tested, it is costly, inefficient, and requires a high degree of operator competence.…”

Section: Introductionmentioning

confidence: 99%

A precise measurement method for tube endpoints based on spatial geometry and perspective projection model

Zhao¹,

Xia²,

Chen³

et al. 2022

Meas. Sci. Technol.

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Tubes are widely used in the aerospace field for such things as engines, fuel pipelines, cooling systems, etc. To improve manufacturing efficiency and accuracy, researchers develop multi-camera vision methods for measuring tube geometry parameters. However, these methods cannot measure the exact position of the endpoints of the tube because the projection points of the tube endpoints have no obvious texture features in the image. To solve the above problem, a precise measurement method for tube endpoints based on spatial geometry and perspective projection model is proposed in this paper. First, we establish a Plücker coordinate system, which treats the end of the tube as a cylinder. Then, several line equations parallel to the center line are calculated on the surface of the cylinder, and their intersections with the end face are obtained on these lines, which refer to the optical center of the camera, the radius of the tube, etc. These intersections are projected onto the centerline and optimized to get the endpoint. Finally, we build a multi-camera vision measurement system consisting of 10 industrial cameras to verify the effectiveness of the proposed method. Extensive experiments have shown that the average error of this method is within 0.1 mm and the standard deviation is within 0.08 mm, which proves the superiority of our proposed method.

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In-process measurement of springback in tube rotary draw bending

Cited by 19 publications

References 31 publications

Additive Manufacturing of Polymeric Pressure Die For Rotary Draw Bending Process

Additive Manufacturing of Polymeric Pressure Die For Rotary Draw Bending Process

Inline Monitoring of the Geometry of Free-form Bent Components

A precise measurement method for tube endpoints based on spatial geometry and perspective projection model

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