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Smart tooling for sheet metal press forming in low production volumes

Objective


Work package 1 resulted in a decision support system for selecting the right tooling. Here, an inventory was made of all possible expert systems, materials, shaping and finishing techniques (task1.1). Guidelines were developed and used in building a predictive model (task 1.2). This model was further elaborated into a tooling decision support system (task 1.3) based on the results of the tooling technique development (task 2.2 and 2.3) and the validated tooling decision support system & tooling technique from work package 3. The second work package resulted in improved tooling techniques. First, the research matrix (materials, processing techniques, etc.) was determined followed by the specification of requirement for the various materials and techniques. Task 2.2 and 2.3 were meant to fill in the knowledge gaps in material behaviour, processing and finishing techniques as well as to expand the applicability (working area) of the non-conventional materials by investigating how to process, finish and work with these 'soft' materials. In task 2.4 pilot tests were performed with the prototype tools from task 3.1 and 3.2. Here, the optimal conditions for the press operations were determined as well as the effect of the tooling materials on the drawing process. The final result of work package 2 is best practises for shaping, finishing and pressing with non-conventional materials.

Work package 3 was dedicated to the validation of the developed tooling decision support system and the tooling techniques. Actual product designs were chosen by the project partners to validate the DSS, i.e. material selection, tooling design and the way to prepare (shaping & finishing) the tooling (task 3.1). The tooling were manufactured in task 3.2 and used for pilot testing in task 2.4. The results of the pilot tests were used to validate the tools in task 3.3. Work package 4 resulted in an integrated Smart tooling decision support system with existing CAD/CAM systems. Concluding the project an economic impact assessment was made of the developed Smart tooling decision support system and the developed tooling techniques.

According to the participants, the project has generated three exploitable results, i.e.
- an accurate Decision Support System assisting in the design of soft tooling(s) for deep drawing processes (for various plate materials), also predicting the life time and production cost of the tooling(s);
- hands-on experience with low-cost tooling techniques;
- increased knowledge on new (soft) tool materials.

Funding Scheme

CRS - Cooperative research contracts

Coordinator

FLEX-O-THERM B.V.
Address
36,Zelhemseweg 36
7255 PT Hengelo Gld
Netherlands

Participants (8)

FERROPRESS B.V.
Netherlands
Address
Gesinkkampstraat
7051 HP Varsseveld
HUSKVARNA PROTOTYPER AB
Sweden
Address
Drottninggatan 2
Husvarna
INSTITUTE OF MECHANICAL ENGINEERING AND INDUSTRIAL MANGEMENT
Portugal
Address
Rua Do Barroco 174/214
4465-591 Sao Mamede De Infesta
MOLDECAR - INDUSTRIA DE MOLDES LDA
Portugal
Address
Zona Industrial De Maia I, Sector X, Arh.5
4470 Maia
NETHERLANDS ORGANISATION FOR APPLIED SCIENTIFIC RESEARCH - TNO
Netherlands
Address
501,Laan Van Westenenk 501
7300 AM Apeldoorn
OBO-WERKE GMBH & CO. KG
Germany
Address
Am Bannhof 5
31655 Stadthagen
P.J. FERRAMENTAS, LDA
Portugal
Address
Rue De Paz, Quinta De Loureiro, Cacia
3801-801 Aveiro/eixo
PROVEN CONCEPTS B.V.
Netherlands
Address
De Haak 6
5555 XK Valkenswaard