On the opportunities of problem- and process-adapted shear cutting simulations for effective process design

Krinninger, Michael; Opritescu, Daniel; Golle, Roland; Volk, Wolfram

doi:10.1016/j.proeng.2017.10.1080

Cited by 10 publications

(5 citation statements)

References 3 publications

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“…The main directions of process improvements to obtain the geometric accuracy of the workpieces are considered in the works [1,[5][6]. The main directions of scientific research [12][13][14][15][16] were: the creation favorable of metal stress state in the cutting zone and; the development of new designs of stamp and cutting tools.…”

Section: Introductionmentioning

confidence: 99%

Development and research of the stamp for cutting of a rolled stock with a differentiated clamp

Karnaukh¹,

Марков²,

Shapoval³

et al. 2022

FME Transactions

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The work aims to develop and research a stamp with a differentiated clamp of a rolled stock for cutting by shear. A new stamp design with a differentiated clamp of the rolled stock has been developed. In terms of their technical and economic indicators, these stamps meet or exceed the modern samples of similar punch tools. At the same time, in the process of vertical cutting, a constant position of the rolled stock axis is ensured. The transmission of force to the clamp through the rolled stock is excluded. The stamp design ensures its sufficiently high rigidity and relatively small overall dimensions. Based on the analysis of the mathematical model of a stamp with a differentiated clamp, the effective angles of force transmission to the clamp and the cutting of the rolled stock between the stamp parts have been established. The resulting model was used to optimize the angles of force transfer to the clamp, and the cutting rolled stock, respecting the force from the side of a buffer and the minimum required press force. At the same time, the vertical stroke of the moving parts is reduced, the overall dimensions of the stamp are decreased, and the buffer also has a minimum size. To reduce the required force of the press, it is necessary to reduce the value of a frictional slipping coefficient by using antifriction materials on contact surfaces and ensuring good lubrication conditions. The results of the conducted experiments confirm the adequacy of the mathematical model. The value of the required force on the press slide available from experiments is slightly higher than the values obtained by the developed analytical model. The results of the stamp implementation show that: the stamps are efficient and reliable in exploitation; the quality of the cutoff workpieces corresponds to the quality indicators of the workpieces cut on similar modern equipment.

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Section: Introductionmentioning

confidence: 99%

Development and research of the stamp for cutting of a rolled stock with a differentiated clamp

Karnaukh¹,

Марков²,

Shapoval³

et al. 2022

FME Transactions

View full text Add to dashboard Cite

show abstract

“…Different experiments with different parameters show either an increase or a decrease in the cutting edge/surface parameters and thus come to contradictory conclusions; the high-dimensional parameter space renders comparison and interpretation of the results very difficult. Facing shorter product life cycles and customer-oriented serial production, it is important to improve the manufacturing process by an automated quality monitoring [3,[12][13][14].…”

Section: Introductionmentioning

confidence: 99%

Optical inline monitoring of the burnish surface in the punching process

Lorenz

Menzl

Donhauser

et al. 2021

Int J Adv Manuf Technol

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Punching is a wide-spread production process, applied when massive amounts of the ever-same cheap parts are needed. The punching process is sensitive to a multitude of parameters. Unfortunately, the precise dependencies are often unknown. A prerequisite for optimal, reproducible and transparent process alignment is the knowledge of how exactly parameters influence the quality of a punching part, which in turn requires a quantitative description of the quality of a part. We developed an optical inline monitoring system, which consists of a combined imaging and triangulation sensor as well as subsequent image processing. We show that it is possible to capture images of the cutting surface for every part within production. We automatically derive quality parameters using the example of the burnish height from 2D images. In addition, the 3D parameters are calculated and verified from the triangulation images. As an application, we show that the status of tool wear can be inferred by monitoring the burnish height, with immediate consequences for predictive maintenance. Although limited by slow images processing in our prototype, we conclude that connecting machine and process parameters with quality metrics in real time for every single part enables data-driven process modelling and ultimately the implementation of intelligent punching machines.

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“…Moreover, the wide variety of machine-, tool-, material-and process-parameters and their mutual dependencies render it very difficult to compare the results of different process studies. [3,7,8] Fig. 2: Selection of process parameters that are most likely to influence the cutting surface parameters The influence of these process parameters, lack of an accurate prediction of material separation and rigidity requirements from the process also complicate the design and dimensioning of the stamping tool [9,8].…”

mentioning

confidence: 99%

“…[3,7,8] Fig. 2: Selection of process parameters that are most likely to influence the cutting surface parameters The influence of these process parameters, lack of an accurate prediction of material separation and rigidity requirements from the process also complicate the design and dimensioning of the stamping tool [9,8]. Therefore, the tool designs are based on the empiric model in [10].…”

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confidence: 99%

Towards Data Driven Stamping Process Modelling by Optical Inline Monitoring of Cutting Surface Parameters

Lorenz

Menzl

Donhauser

et al. 2021

Preprint

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Stamping is a wide-spread production process, applied when massive amounts of the ever-same cheap parts are needed. For this reason, a highly efficient process is crucial. The cutting process is sensitive to a multitude of parameters. A process that is not correctly adjusted is subject to considerable wear and therefore not efficient. Unfortunately, the precise dependencies are often unknown. A prerequisite for optimal, reproducible and transparent process alignment is the knowledge of how exactly parameters influence the quality of a cutting part, which in turn requires a quantitative description of the quality of a part. A data driven approach allows to meet this challenge and quantify these influences. We developed an optical inline monitoring system, which consists of a image capturing, triangulation and image processing, that is capable of deriving quality metrics from 2D images and triangulation data of the cutting surface, directly inside the machine and without affecting the process. We identify features that can be automatically turned into quality metrics, like fraction of the burnish surface or the cut surface inclination. As an application, we show that the status of tool wear can be inferred by monitoring the burnish surface, with immediate consequences for predictive maintenance. Furthermore, we conclude that connecting machine and process parameters with quality metrics in real time for every single part enables data driven process modelling and ultimately the implementation of intelligent stamping machines.

show abstract

On the opportunities of problem- and process-adapted shear cutting simulations for effective process design

Cited by 10 publications

References 3 publications

Development and research of the stamp for cutting of a rolled stock with a differentiated clamp

Development and research of the stamp for cutting of a rolled stock with a differentiated clamp

Optical inline monitoring of the burnish surface in the punching process

Towards Data Driven Stamping Process Modelling by Optical Inline Monitoring of Cutting Surface Parameters

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