Next Generation Deep Drawing Using Smart Observers, Close-Loop Control, and 3D-Servo-Press

使用智能观察器、闭环控制和 3D 伺服压力机的下一代深拉伸

基本信息

批准号：
386415239
负责人：
Professor Dr.-Ing. Peter Groche
金额：
--
依托单位：
Institut für Produktionstechnik und Umformmaschinen
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2017
资助国家：
德国
起止时间：
2016-12-31 至 2021-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/386415239?language=en
关键词：
Next Generation Deep Drawing Using

项目摘要

The objectives of this collaborative research project are to (i) exploit the flexibility of a 3D-servo-press to improve the formability of sheet metal components, (ii) establish the scientific understanding to identify non-linear 3D blank holder (BH) movements causing non-linear deformation-paths for material formability improvements, (iii) determine adequate sensor/observer structures to predict wrinkling and tearing failures in sheet metal components, and (iv) create a framework for Industry 4.0 process implementation and benefits. With the aid of the automatic adjustment of processes with respect to variations in the material and process conditions in real time failure sheet metal can be avoided, improvements in the dimensional accuracy and final properties of products can be achieved, and ultimately scrap-rates can be reduced. The research will capitalize on the strengths of the two institutions with respect to forming machines at PtU and material characterization and modeling at UNH. Personnel exchanges will provide exceptional educational and cultural opportunities for the researchers involved and will assure the success of the collaboration. In this research, Industry 4.0 components, i.e. sensors/observers, control systems, and actuators, will be investigated to improve sheet metal forming. The specific tasks that will be completed are: (T1) Characterize the material behavior, including the predictions of both tearing and wrinkling failures using an acoustic emission sensor. This task also includes understanding failure in the material when subjected to non-linear deformation-paths which are common in sheet metal forming processes. (T2) A novel deep drawing process enabling non-linear BH-movements will be established and equipped with control and observer systems. Specially designed tooling will allow various non-linear deformation-paths to be achieved through non-linear BH movements of a unique 3D-servo-press. (T3) Conduct numerical simulations to determine beneficial non-linear 3D BH movements offline. For improved real-time process control, reduced-order models for selected observers will also be created and validated. They allow for predicting key process parameters that cannot be measured experimentally, e.g., stress and strain values, based on an evaluation of sensor data. (T4) Control schemes and systems will be compared with respect to product properties and process robustness. These include feed-forward and different closed-loop control approaches to determine the desired actuator trajectories.The knowledge gained from this research will benefit Industry 4.0 efforts and improve product design and manufacturing.

该协作研究项目的目标是（i）利用3D-Servo-Press的灵活性来提高钣金组件的形成性，（ii）建立科学理解，以确定非线性3D空白持有人（BH）运动（BH）运动，从而导致非线性变形，以预测实质性的表现，以预测适当的撕裂，（III II），（iii II），（iii II），（iii II）组件和（iv）为行业4.0流程实施和收益创建一个框架。借助自动调整工艺在实时故障板金属中的材料和过程条件方面的变化方面，可以避免，可以提高尺寸准确性和产品的最终性能，并最终可以降低废料率。这项研究将利用这两个机构在PTU的成型机以及UNH的材料表征和建模方面的优势。人事交流将为参与的研究人员提供卓越的教育和文化机会，并确保合作的成功。在这项研究中，将研究工业4.0组件，即传感器/观察者，控制系统和执行器，以改善金属形成。要完成的特定任务是：（T1）表征材料行为，包括使用声发射传感器的撕裂和皱纹失败的预测。此任务还包括了解材料中的故障，遭受在钣金形成过程中常见的非线性变形路径。（T2）将建立并配备一种具有控制和观察者系统的新型深度绘图过程，并建立了非线性BH运动。专门设计的工具将允许通过独特的3D-Servo压力的非线性BH运动来实现各种非线性变形路径。（T3）进行数值模拟，以确定有益的非线性3D BH运动离线。为了改善实时过程控制，还将创建和验证选定的观察者的减少订单模型。它们允许根据传感器数据的评估来预测无法通过实验测量的关键过程参数，例如应力和应变值。（T4）将在产品属性和过程鲁棒性方面进行控制方案和系统。其中包括馈送前进和不同的闭环控制方法，以确定所需的执行器轨迹。这项研究所获得的知识将使行业4.0的努力受益并改善产品设计和制造。

项目成果

期刊论文数量（3）

专著数量（0）

科研奖励数量（0）

会议论文数量（0）

专利数量（0）

Robustness of deep-drawing finite-element simulations to process variations

DOI：
10.1007/s12289-022-01695-3
发表时间：
2022-05
期刊：
International Journal of Material Forming
影响因子：
2.4
作者：
Kelin Chen;A. Breunig;J. Ha;B. Kinsey;P. Groche;Y. Korkolis
通讯作者：
Kelin Chen;A. Breunig;J. Ha;B. Kinsey;P. Groche;Y. Korkolis

Effectiveness of different closed-loop control strategies for deep drawing on single-acting 3D Servo Presses

单动 3D 伺服压力机拉深时不同闭环控制策略的有效性

DOI：
10.1016/j.cirp.2022.04.072
发表时间：
2022
期刊：
CIRP Annals
影响因子：
0
作者：
Groche, Peter;Breunig, Alexander;Chen, Kelin;Molitor, Dirk A.;Ha, Jinjin;Kinsey, Brad L.;Korkolis, Yannis P.
通讯作者：
Korkolis, Yannis P.

AA1100-O cylindrical cup-drawing using 3D servo-press

使用3D伺服压力机进行AA1100-O圆柱杯拉深