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Sheet metal forming process and tools optimisation

Objective



The punch and die stamping process of thin sheet metal is
a widely used forming process in modern industry, ranging
from Automotive to Manufacturing to Aerospace. Modern
alloys increase sheet formability, drawability and
component strength allowing stamping of parts with
complex geometry and high resistance.
The project proposal, included in the programme Area 1
Production Technologies addressing mainly to 1.1
(Incorporation of new technologies into production
systems), consists of the following main research tasks:
Detailed specification of the process requirements
using a press machine tool.
Development of measure and data acquisition devices for
controlling parameters in the press.
Development of monitoring and control devices for the
press.
Prototype design and development to be included in a
standard press focusing on the following objectives:
Design and develop a control device for specific press
parameters mainly related to the whole system (press &
die) such as deformation of the tooling, force and
pressure applied to the blankholder and sheet metal flow.
The device will subsequently be used for controlling a
production forming system. This control device will be
developed on the basis of:
* Data acquisition using sensoring systems.
* Management and monitoring of the data obtained.
Resulting from the data obtained and processed with the
above device, actions will be taken for:
1) Improving the quality of shearing and forming process.
2) Obtaining a continuous feedback for the process which
allows an automatic correction in the subsequent stroke.
3) Obtaining a more flexible pre setting for reducing the
time needed to manufacture a good quality part after a
change of the tools.
4) Securing a statistical control of the process.
5) Increasing the production speed through a better
control of the stamping process.
All the above actions will be achieved through the
control of the different hydraulic and pneumatic systems
of the presses such as the cushions and the blankholder.
Reduction of cycle times in a 10%, minimisation of idle
times up to a 30% and enhancement of part quality in a
20% should be direct and tangible achievements of this
project.
A great innovation is the monitoring and control system
to be fitted on the press that will allow locations and
displacements to be measured even at extremely high
punching speeds by using sensors, and act on the
different elements of the press to correct the potential
errors on next strokes. Noise reduction devices will be
other innovative characteristics of the final product.
The elaborated prototype press with the new systems and
peripherals is expected to be brought to the market
within 12 months after project end and a fully industrial
machine tool is expected to be available within the first
18 months of the exploitation period. The press will be
available to all small, medium and large die stampers,
enabling them to reduce cycle time and to enhance the
quality of stamped parts. This will lead to an
optimisation and cost and time reduction for the forming
process and part, which will be of direct benefit for a
very wide range of European industries.

Call for proposal

Data not available

Coordinator

FAGOR ARRASATE, S. COOP.
Address
20,bo San Andres 20
20500 Mondragon
Spain

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Participants (3)

Gestamp Noury SA
France
Address

77220 Tournan En Brie

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Robotiker - Technological Transfer Centre
Spain
Address

48170 Zamudio

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University of Manchester Institute of Science and Technology (UMIST)
United Kingdom
Address
Sackville Street
M60 1QD Manchester

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