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Cost efficient and ecological sustainable light weight sheet metal forming by employing an intelligent pulsating blankholder technology

Exploitable results

Objective/Potential applications The result is a sensor-equipped tool with special inlays for the drawing of high strength steel. Application in automotive, aircraft and consumers articles industry. End-user Manufacturer of metal sheet parts of above mentioned industries. Main Innovations The system shows clear advantageous compared with a conventional process when drawing stainless steel and high strength steel on the drawing of an oil pan. In the special case this resulted in: material reduction: the material thickness in oil pan production could reduced by 30%; productivity: the drawing deep could be increased by 25%, so deep drawing steps could be saved; product quality: the part strength was increased by increasing the strength of the weakest edge by 4,5%. Analysis of market Neff planned to sale 6PBH systems per year. Estimating that for 2-3 applications are running per system 12-18 tools per year could be requested. Potential barriers When reaching the project targets no barriers should limit the exploitation.
Objective/Potential applications The result of the work is novel system providing minimised average blank holder force, optimised frequency and amplitude. Application in automotive, aircraft and consumers articles industry. End-user Manufacturer of metal sheet parts of above mentioned industries. Main Innovations The system shows clear advantageous compared with a conventional process when drawing stainless steel and high strength steel on the drawing of an oil pan. In the special case this resulted in: material reduction: the material thickness in oil pan production could reduced by 30%; productivity: the drawing deep could be increased by 25%, so deep drawing steps could be saved; product quality: the part strength was increased by increasing the strength of the weakest edge by 4,5%. Analysis of market Estimated market for NEFF from 2006: Installation size 2000kN, ca. 370t€/press (each 2 per year) Installation size 4000kN, ca. 500t€/press (each 2 per year) Installation size 6000kN, ca. 800t€/press (each 2 per year) Potential barriers When reaching the project targets no barriers should limit the exploitation.
Objective/Potential applications Aim: To develop a pc-based process control system with tele-service capabilities for a novel pulsating blank holder (PBH) system. Objectives: - To design and manufacture a sensor system for the deep drawing tool and equip it with a real-time data acquisition device. - To develop software to capture the signals and control the process in real-time by detection and subsequent prevention of tears and wrinkles. - To provide the control of the system remotely via Internet. To meet these objectives, a sensor system for the deep drawing tool, capable of measuring the process parameters (BHF, drawing force, temperature, etc.) has been designed, manufactured and tested. The system has a real-time data acquisition facility which can acquire the signals and provide data analysis to detect the failure modes (tears and wrinkles), and therefore, can provide feedback on the status of product quality. The system is capable of being remotely controlled over the Internet. The lab-scale tests revealed a moderate degree of success in increasing the draw depth provided the correct pulsing frequency and amplitude are selected. It was found that particular attention must be paid to synchronising the pulsing force with the peak of the punch force. The control strategy is based on analysis of sensor signals, which will determine if a wrinkle or tear has occurred. The pulsating force is then adjusted to ensure that next component is sound. Application in automotive and consumers articles industry. End-user Manufacturer of metal sheet parts of above mentioned industries Main Innovations - A sensor system to measure the process parameters has been completed and shown to operate satisfactorily. - Real-time data acquisition and software code has been developed to capture the signals. - On-line processing of the captured data and extraction of process information has been completed and shown to work well. - Failure detection software to identify the tears and wrinkles, if present, has been written and tested with satisfactory results. - A remote control feature for the system to be controlled over the Internet has been created and tested successfully. Potential barriers When reaching the project targets no barriers should limit the exploitation
Objective/Potential applications Convergent numerical algorithms predicting forming process of model parts with a maximum deviation of 5-10% integrated in ABAQUS and PAM-STAMP. Prediction of wall thickness distribution and surface effects (wrinkles, tears). Application in automotive and consumers articles industry. End-user Manufacturer of metal sheet parts of above mentioned industries and toolmakers. Main Innovations Simulation of deep drawing process with a pulsating blankholder force. Analysis of market Automotive, kitchen appliances, consumer goods (part development - make-ability studies; tooling and process design). Potential barriers When reaching the project targets no barriers should limit the exploitation
Objective/Potential applications Test apparatus for pulsating friction tests in which the sliding contact between sheet and tool is simulated. A model that describes the relationships between the friction forces on the sheet surface Application is in wear and friction studies for selection and development of tribo- systems for PBH processes as well as for modelling the friction in PBH process simulations. End-user Developers of deep drawing processes with advanced blankholder control (for manufacturing of automotive parts, household and consumer goods). Developers of lubricants, tooling and sheet materials, coatings. Main Innovations Incorporation of close-loop controlled hydraulic pulsating normal force in TNO Slider-on-sheet tribometer and pulsating contact friction measurements for sheet metal forming. Analysis of market Automotive, kitchen appliances, consumer goods (part development - make-ability studies; tooling and process design). Lubricant and coating manufacturers. Potential barriers When reaching the project targets no barriers should limit the exploitation

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