Optical Measuring Technologies in Sheet Metal Processing

Galanulis, Konstantin

doi:10.4028/0-87849-972-5.19

Cited by 12 publications

(10 citation statements)

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“…Since measurements of complex 3-d components in the body-inwhite are time consuming and cannot take place inline after every process step, offline measured data by means of 3-d scanning [18] were accompanied with simulation results of the shape variation during mechanical treatment and joining [9]. In this way a probable tolerance spectrum could be generated in order to create a basis for the tolerance chain analysis.…”

Section: Digital Methods To Comprise the Error Sources In Manufacturingmentioning

confidence: 99%

A computer aided chaining approach for predicting the shape accuracy in manufacture of automotive structures

Papadakis

2010

Prod. Eng. Res. Devel.

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The increasing competition and the urge to reduce costs and shorten product-life-cycles in the automotive industries imply the application of virtual manufacturing mock-ups. Computer aided engineering methods including simulations of the structural behavior during manufacturing and assembly contribute to eliminate trialand-error along the production chains of vehicle structures. Such digital mock-ups also provide an input for additional tolerance analyses and allow the identification of the pending quality of structure components in advance. In this way large numbers of experiments and adjustments on the existent production lines can be avoided. In this paper an approach is introduced, which allows the replication of the physical effects along manufacturing chains based on thermo-mechanical models. The rendered results after considering successive operational steps provide the basis for initial estimations regarding the shape accuracy of structure assemblies. For a specific example of the automotive body-in-white a first run of a manufacturing process chain is investigated in order to predict the shape quality of a probable production cycle by applying a tolerance chain analysis. The results enable the scrap identification due to non-satisfied quality of assemblies. Finally, based on the achieved results a re-engineering of the manufacturing chain is suggested in order to fulfill quality requirements.Keywords Computer aided engineering Á Body-in-white Á Tolerance chain analysis 1 Background and motivation A major aim of production plants is to continuously preserve high efficiency and product quality in order to retain competitiveness and achieve maximum profitability. A central sector in automotive industries and particularly where high reproducibility is feasible and concurrently high product quality is required, is the body-in-white [1].In order to identify errors and predict inaccuracy of the final product, different methods have been developed to observe product quality along the manufacturing process chain. For this purposes an online acquisition of key quality attributes in the body-in-white with the aid of sensor systems concerning i.e. apparatus setups, material properties or semi-product accuracy is recommended [2]. Moreover such quality characteristics can be estimated in advance by applying computer aided methods, initially for single manufacturing operations and afterwards for complete manufacturing chains of major assemblies of modern automotive light-weight structures [3].Virtual manufacturing mock-ups are nowadays widely used to support production lines. They may span optimization algorithms to define successive steps within a manufacturing operation [4] or virtual reality programming in order to enable tele-presence [5]. Furthermore, simulations with the aid of the finite element analysis allow the replication of the mechanical and heat effects of manufacturing and assembly tasks [6,7] up to the crash properties of frame structures [8]. Such digital mock-ups can additionally contribute to the qua...

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Section: Digital Methods To Comprise the Error Sources In Manufacturingmentioning

confidence: 99%

A computer aided chaining approach for predicting the shape accuracy in manufacture of automotive structures

Papadakis

2010

Prod. Eng. Res. Devel.

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“…For the coordinate determination of the reference targets using the bundle adjustment, the circular markers have to be identified uniquely in the different images (Fig. 4), to make sure that they can be related to each other [13][14][15]. The goal is to have an automated identification to eliminate a time consuming and erroneous manual procedure.…”

Section: Circular Markersmentioning

confidence: 99%

“…Since the 3D coordinates of the surface are measured, the actual deformed shape is documented, and the resultant material thinning is calculated using the constant volume assumption [14].…”

Section: Principle Of Optical Measurementmentioning

confidence: 99%

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

2009

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The use of optical measurement equipment and software based on photogrammetry is becoming more affordable and is increasing their reliability in presenting results on surfaces topography as well as strain distribution. The question is, how feasible can their support be to the process/product development engineer in the choice of the right auto body-in-white (BIW) component design; how can they influence blank and tool geometries, process parameters and moreover the right material selection, in order to reduce the springback of such materials on drawing, reaching the required quality standards for the part. This paper describes some industrial cases on how these new techniques can be applied to lay out industrial deep drawing processes, accomplished by the use of optical measurement, improving design and process issues.

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“…In this way, the heat effects during welding are negligible and the contact interaction between the parts due to dimensional inaccuracies can be solely investigated. The geometry of the surface of the two sheet metal components was optically captured as introduced in relevant literature [15]. It is then available in the form of a scatter-plot (STL format).…”

Section: Shape Inaccuracies Due To Preliminary Forming Processesmentioning

confidence: 99%

Simulation of the manufacturing process chain of welded frame structures

Zaeh

Papadakis

Langhorst

2008

Prod. Eng. Res. Devel.

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Numerical solutions of manufacturing process chains strongly focus on supporting the production of frame structures in the vehicle industry. Frame structures play a central role in all means of transportation, dominating the total mass in automobiles, trains, airplanes, and even space ships. In the case of automobiles, the frame structure mass constitutes about 30% of the total mass. In the case of the automotive industry, the mass-production, the high-quality standards and the need for mass minimization all increase the necessity to apply virtual manufacturing methods in the production cycle of frame structures. In scope of this paper, a method of chaining the numerical analysis of the structural effect on frame components during successive manufacturing processes is introduced. The change of thermal, metallurgical, and mechanical properties in structures during manufacturing is analyzed by applying theoretical models depending on the identified problem.

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Optical Measuring Technologies in Sheet Metal Processing

Cited by 12 publications

References 0 publications

A computer aided chaining approach for predicting the shape accuracy in manufacture of automotive structures

A computer aided chaining approach for predicting the shape accuracy in manufacture of automotive structures

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

Simulation of the manufacturing process chain of welded frame structures

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