Smart sheet metal forming
When it comes to forming different sheet metal parts, highly automated press systems, or dies, are needed to satisfy increasing demands on quality and productivity. Current methods rely on trial-and-error and require a skilled operator to adjust the die for the different metal components. The EU-funded 'Self-learning sheet metal forming system' (LEARNFORM) project have addressed this gap in the market. The researchers developed an adaptive die that can quickly learn how to form a new shape without wrinkles and cracks and moreover, with no human intervention. Strategically-placed temperature sensors are able to detect hot spots, or stressed areas, on the metal shape. The rest of the machine uses this information to adjust the forming, clamping and friction systems to reduce the stress on the metal and avoid imperfections. The main advantage of the LEARNFORM product is that it results in a shorter set-up time when switching between different metal parts. Manufacturers will also save on material and energy inputs, and no expertise is required to operate the press. Although it is still only in a prototype phase, researchers expect the product to eventually attract worldwide interest from the automotive, aerospace and appliance industries.
