Abstract
The paper presents a method for checking the geometry of stamped car body parts using a 3D optical measurement system. The analysis focuses on the first forming operation due to the deformation and material flow associated with stall thresholds. An essential element of the analysis is determining the actual gap occurring between the forming surfaces based on the die and punch geometry used in the first stamping operation. The geometry of car body elements at individual production stages was analyzed using an optical laser scanner. The control carried out in this way allowed one to correctly position the tools (punch and die), thus introducing the correction of technological parameters, having a fundamental influence on the specific features of the final product. This type of approach has not been used before to calibrate the technological line and setting of shaping tools. The influence of the manufactured product geometry in intermediate operations on the final geometry features was not investigated.
Highlights
The plastic forming of sheet metal in a multi-operation stamping process is essential in producing car body elements
Body parts are formed in a multi-operation stamping process, during which stamping and cutting operations are carried out, including the punching and cutting off technological allowances
Using an optical measurement system to measure geometries and their comparison to determine deviations supports the process of the precise geometry matching of toolsets at the production start-up stage
Summary
The plastic forming of sheet metal in a multi-operation stamping process is essential in producing car body elements. Due to high-quality requirements, which the final products must meet, more and more emphasis is being placed on the dimensional and shape accuracy, allowing a correct final product [1,2,3,4]. The requirements concerning the accuracy of dimensions and shape are essential in the case of products such as cars [5,6,7], which are mass-produced, and their bodies consist of dozens of elements pressed from steel or aluminum sheets [8]. Body parts are formed in a multi-operation stamping process, during which stamping and cutting operations are carried out, including the punching and cutting off technological allowances. From the point of view of geometric shaping, two technological operations are crucial: the first one is the deep drawing operation, during which the basic shape of the product is given, and the second one is the last drawing operation, during which the final shape of the product is given [11]
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