Abstract
Cost and time for die tryout are significant within the car industry, and elastic deflections of dies and presses are most commonly not considered during the virtual die design and forming simulation phase. Because of this, active surfaces of stamping dies are only cambered based on previous experiences of tool types and presses. However, almost all stamping dies and presses are unique, and available experiences are not valid for new materials. Partners within the Eureka SMART Advanced Manufacturing research project CAMBER have developed advanced deflection measuring devices to quantify the elastic deformations of presses. Using these measurements, cambering methodologies can be utilized in sheet metal forming simulations. Important breakthroughs in recent years enabling the cambering methodology consists of efficient simulation strategies for full scale simulations with elastic dies and optimization techniques for creating substitutive press structures based on measurements. Furthermore, modern press deflection measurement methods are beneficial in applications such as Industry 4.0, predictive maintenance, product quality control, etc. through a more advanced understanding and live monitoring of the press system.
Highlights
Cost and time for die tryout are significant within the car industry, and elastic deflections of dies and presses are most commonly not considered during the virtual die design and forming simulation phase
Active surfaces of stamping dies are only cambered based on previous experiences of tool types and presses
Important breakthroughs in recent years enabling the cambering methodology consists of efficient simulation strategies for full scale simulations with elastic dies and optimization techniques for creating substitutive press structures based on measurements
Summary
Cost and time for die tryout are significant within the car industry, and elastic deflections of dies and presses are most commonly not considered during the virtual die design and forming simulation phase. Because of this, stamping dies are only cambered based on previous experiences of tool types and presses. Published under licence by IOP Publishing Ltd have in common that they, apart from blank and elastic die, need to include numerical representations of the elastic press structure, e.g. Partners within the SMART Advanced Manufacturing research project CAMBER have developed deflection measuring devices based on two different sensor technologies to quantify the elastic deformations of presses. These substitutive models will be important in creating efficient FE models utilized for cambering of stamping dies. Apart from the above mentioned advantages for die virtual spotting and cambering, the new measuring techniques enables the inline measurement of press deflections and health monitoring of the whole system. The stiffness loss or press deflections increase in combination with stamping forces evolution are useful information for early detection of machine breakdowns
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