New trends in sheet metal forming analysis and optimization trough the use of optical measurement technology to control springback

Damoulis, Gleiton Luiz; Gomes, Érica Alves; Batalha, Gilmar Ferreira

doi:10.1007/s12289-009-0413-0

Cited by 7 publications

(7 citation statements)

References 9 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…By this innovative process class parts derived from components such as synchronizer rings used in gear boxes can be manufactured in short process chains. Forward extrusion (FE) and lateral extrusion (LE) are considered to be core processes of bulk forming [7], as is deep drawing [8] for sheet-metal forming. By combining both processes local differences in forming conditions [6] result in insufficient control of the material flow in SBMF, which reduces the achievable geometric workpiece accuracy especially of the functional elements [9] and often necessitates rework.…”

Section: Introductionmentioning

confidence: 99%

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Pilz¹,

Henneberg²,

Merklein³

2020

Manufacturing Rev.

View full text Add to dashboard Cite

Increasing demands in modern production pose new challenges to established forming processes. One approach to meet these challenges is the combined use of established process classes such as sheet and bulk forming. This innovative process class, also called sheet-bulk metal forming (SBMF), facilitates the forming of minute functional elements such as lock toothing and gear toothing on sheet-metal bodies. High tool loads and a complex material flow that is hard to control are characteristic of SBMF. Due to these challenging process conditions, the forming of functional elements is often insufficient and necessitates rework. This negatively affects economic efficiency. In order to make use of SBMF in industrial contexts, it is necessary to develop measures for improving the forming of functional elements and thereby push existing forming boundaries. This paper describes the design and numerical replication of both a forward and a lateral extrusion process so as to create involute gearing in combination with carrier teeth. In a combined numerical-experimental approach, measures for extending the die filling in sheet-metal extrusion processes are identified and investigated. Here, the focus is on approaches such as process parameters, component design and locally adjusted tribological conditions; so-called 'tailored surfaces'. Based on the findings, fundamental mechanisms of action are identified, and measures are assessed with regard to their potential for application. The examined approaches show their potential for improving the forming of functional elements and, consequently, the improvement of geometrical accuracies in functional areas of the workpieces. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

show abstract

Section: Introductionmentioning

confidence: 99%

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Pilz¹,

Henneberg²,

Merklein³

2020

Manufacturing Rev.

View full text Add to dashboard Cite

show abstract

“…One such process technology that applies bulk forming operations on semi-finished sheet metal products is the so-called sheet-bulk metal forming (SBMF) [5]. Forward (FE) and lateral extrusion (LE) [6] are considered to be the standard processes for bulk and deep drawing [7] for sheet metal forming. The potential of sheet bulk metal forming is currently of only limited use.…”

Section: Introductionmentioning

confidence: 99%

Influence of component design on extrusion processes in sheet-bulk metal forming

Pilz

Merklein

2019

Int J Mater Form

View full text Add to dashboard Cite

Nowadays, the functional integration of workpieces challenges existing forming processes. The combination of established forming processeslike sheet metal and bulk formingoffers the possibility to counter this issue. The application of bulk forming operations on sheet metal semi-finished products, also called sheet-bulk metal forming (SBMF), is an innovative approach. The potential of SBMF cannot be fully exploited, as there are no recommendations in terms of workpiece design and layout influence on the process result. Therefore, this paper focuses on the analysis of semi-finished products and component design parameters on resulting part and process properties in two extrusion processes in SBMF. The investigation is based on a combined numerical and experimental approach. It is shown that the investigated design parameters, in addition to the achievable dimensional accuracy, substantially influence the occurring tool loads as well as the required process forces.

show abstract

“…In industry, the development of non‐contact three‐dimensional (3D) measuring technology has provided another way for fast springback analysis. This technique is becoming more affordable and reliable in providing surfaces topography as well as strain distribution . As it can be used to detect the practical springback distortion of the stamped part and to perform strain analysis within critical stamping part areas, it has been used increasingly for the design of automotive components in the try‐out process .…”

Section: Introductionmentioning

confidence: 99%

A Semi‐Analytic Model to Predict and Compensate Springback in the 3D Stretch Bending Process

Liao

Xue

Zhou

et al. 2013

steel research int.

View full text Add to dashboard Cite

With the increase of using aluminum alloys and high strength steels to replace traditional steels, precise prediction of sheet springback and corresponding compensation methods become more and more important for die design because these material' s higher ratio of yield strength to elastic modulus causes more serious springback problems. In this paper, a semi‐analytic springback prediction and compensation model based on in‐process measurement is proposed. For springback prediction, measured strain and curvature data from the actual stamping process are incorporated in a semi‐analytic model, and then springback is predicted based on the elastic unloading from the residual differential stress during sheet metal forming. In the next stage of die design, a procedure to automatically compensate the tool geometry, including the fundamental mechanics analysis and the reconstruction of the tool surface, is presented. For validation purpose, a case study was carried out for the tool optimization of a double curved panel.

show abstract

New trends in sheet metal forming analysis and optimization trough the use of optical measurement technology to control springback

Cited by 7 publications

References 9 publications

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements

Influence of component design on extrusion processes in sheet-bulk metal forming

A Semi‐Analytic Model to Predict and Compensate Springback in the 3D Stretch Bending Process

Contact Info

Product

Resources

About