Improved process robustness by using closed loop control in deep drawing applications

Abstract

The production of irregular shaped deep-drawing parts with high quality requirements, which are common in today’s automotive production, permanently challenges production processes. High requirements on lightweight construction of passenger car bodies following European regulations until 2020 have been massively increasing the use of high strength steels substantially for years and are also leading to bigger challenges in sheet metal part production. Of course, the more and more complex shapes of today’s car body shells also intensify the issue due to modern and future design criteria. The metal forming technology tries to meet these challenges by developing a highly sophisticated layout of deep drawing dies that consider part quality requirements, process robustness and controlled material flow during the deep or stretch drawing process phase. A new method for controlling material flow using a closed loop system was developed at the IFU Stuttgart. In contrast to previous approaches, this new method allows a control intervention during the deep-drawing stroke. The blank holder force around the outline of the drawn part is used as control variable. The closed loop is designed as trajectory follow up with feed forward control. The used command variable is the part-wall stress that is measured with a piezo-electric measuring pin. In this paper the used control loop will be described in detail. The experimental tool that was built for testing the new control approach is explained here with its features. A method for gaining the follow up trajectories from simulation will also be presented. Furthermore, experimental results considering the robustness of the deep drawing process and the gain in process performance with developed control loop will be shown. Finally, a new procedure for the industrial application of the new control method of deep drawing will be presented by using a new kind of active element to influence the local blank holder pressure onto part flange.