Small Series Production and Geometric Analysis of Sheet Metal Car Body Parts Using Forming Tools Made of Fused Filament Fabricated PLA

A precise production of sheet metal parts has always been a main goal in press shops. Highest quality demands are required especially in automotive production. Unfortunately, even today, the production is not optimal due to an ineffective approach to the springback compensation. Springback results in geometrical shape inaccuracies of the obtained product. Based on the current approach, excessive time and financial costs emerge due to corrections on the press tools. However, these corrections do not always lead to a better accuracy of the stampings. The main objective of the research is to design a modified solution of the current approach. The modified solution is designed as a methodology with a focus on the analysis and compensation of the springback with a help of a numerical simulation. To achieve the main goal, smaller sub-goals are employed. These sub-goals, or rather experiments, mainly focus on parameters, which, more or less, influence the springback phenomenon. The designed methodology is verified with real car body parts and is carried out with a help of the department of the press tools design in ŠKODA AUTO, a.s. There, the methodology is used for improving the accuracy of the stamping process of the car body parts and for improving the quality of the final product.

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Basics for inline measurement of tribological conditions in series production of car body parts

IOP Conference Series Materials Science and Engineering ◽

10.1088/1757-899x/651/1/012050 ◽

2019 ◽

Vol 651 ◽

pp. 012050

Author(s):

B Hansen ◽

M Hoebler ◽

S Purr ◽

J Meinhardt ◽

M Merklein

Keyword(s):

Body Parts ◽

Series Production ◽

Car Body ◽

In Series ◽

Inline Measurement

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Investigations of batch fluctuation regarding tribological conditions in series production of car body parts

International Journal of Material Forming ◽

10.1007/s12289-020-01600-w ◽

2021 ◽

Author(s):

B. Hansen ◽

P. Wagner ◽

S. Purr ◽

M. Merklein

Keyword(s):

Body Parts ◽

Series Production ◽

Car Body ◽

In Series

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AM-Serienproduktion für die Automobilindustrie/AM series production for the automotive industry

wt Werkstattstechnik online ◽

10.37544/1436-4980-2020-11-12-16 ◽

2020 ◽

Vol 110 (11-12) ◽

pp. 752-757

Author(s):

Lukas Weiser ◽

Marco Batschkowski ◽

Niclas Eschner ◽

Benjamin Häfner ◽

Ingo Neubauer ◽

...

Keyword(s):

Additive Manufacturing ◽

Automotive Industry ◽

Series Production ◽

Production Scale ◽

Additive Fertigung ◽

Small Series ◽

Start Up ◽

3D Printed ◽

Component Quality

Die additive Fertigung schafft neue Gestaltungsfreiheiten. Im Rahmen des Prototypenbaus und der Kleinserienproduktion kann das Verfahren des selektiven Laserschmelzens genutzt werden. Die Verwendung in der Serienproduktion ist bisher aufgrund unzureichender Bauteilqualität, langen Anlaufzeiten sowie mangelnder Automatisierung nicht im wirtschaftlichen Rahmen möglich. Das Projekt „ReAddi“ möchte eine erste prototypische Serienfertigung entwickeln, mit der additiv gefertigte Bauteile für die Automobilindustrie wirtschaftlich produziert werden können. Additive manufacturing (AM) offers new freedom of design. The selective laser-powderbed fusion (L-PBF) process can be used for prototyping and small series production. So far, it has not been economical to use it on a production scale due to insufficient component quality, long start-up times and a lack of automation. The project ReAddi aims to develop a first prototype series production to cost-effectively manufacture 3D-printed components for the automotive industry.

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Autonomes Oberflächenschleifen von Aluminium-Anbauteilen/Autonomous grinding of lightweight constructions

wt Werkstattstechnik online ◽

10.37544/1436-4980-2020-07-08-51 ◽

2020 ◽

Vol 110 (07-08) ◽

pp. 507-510

Author(s):

Jan-Oliver Brassel ◽

Severin Hönle ◽

Jürgen Fleischer ◽

Hannah Pulli

Keyword(s):

Sheet Metal ◽

Metal Surfaces ◽

Surface Finishing ◽

Technological Solution ◽

Metal Structures ◽

Car Body

Zum Erfüllen der hohen Anforderungen an fehlerfreie Blechteiloberflächen werden häufig manuelle Aufwendungen in die Fertigstellung der Bauteile investiert. Mit Blick auf Produktivität und Wiederholgenauigkeit sollen Teilumfänge der Fertigstellung automatisiert werden. Inhalt dieses Beitrags ist die Konzeption einer Prozesskette zum autonomen Schleifen von Karosseriebauoberflächen sowie die Betrachtung eines Algorithmus zur Berechnung der Bearbeitungsreihenfolge.   Flawless paintwork on car body structures does require defect-free sheet metal surfaces. Therefore, mainly inline and manual refinement efforts are made to surface finishing the single car bodies before painting. Targeting productivity and repeat accuracy can make it necessary to automate certain amounts of this labour-intensive process. This paper presents a technological solution for autonomously grinding sheet metal structures as well as detailing an algorithm for calculating the sequence of steps for autonomous grinding.

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Aanalysis of springback phenomenon in pipe bending

World Journal of Engineering ◽

10.1260/1708-5284.11.3.229 ◽

2014 ◽

Vol 11 (3) ◽

pp. 229-232

Author(s):

Rahul Hingole ◽

Vilas Nandedkar

Keyword(s):

Sheet Metal ◽

Research Work ◽

Deep Understanding ◽

Beam Theory ◽

New Approach ◽

Metal Parts ◽

Sheet Metal Parts ◽

Before And After ◽

Forming Tools ◽

Pipe Bending

The term springback is defined as the change in geometry of a component after forming, when the forces are removed from forming tools. As springback affects the final shape of the part, it can lead to significant difficulties in the assembly of component when springback is not proper. This problem leads to fabrication of inconsistent sheet metal parts; the elastic strain recovery in the material after the tooling is removed. Bendingis the plastic deformation of metals about a linear axis called the bending axis with little or no change in the surface area. Bending types of forming operations have been used widely in sheet metal forming industries to produce structural stamping parts such as braces, brackets, supports, hinges, angles, frames, channel and other nonsymmetrical sheet metal parts. Among them, quite a few efforts have been made to obtain a deep understanding of the springback phenomenon. The beam theory has been applied to formulate the curvature before and after loading of pipe. This research work has focused on study effect of springback effect with a new approach. The ANSYS software is used to analyze spring back effect. The detail study of this springback effect is presented in this paper.

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Stamping Plant 4.0 – Basics for the Application of Data Mining Methods in Manufacturing Car Body Parts

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.639.21 ◽

2015 ◽

Vol 639 ◽

pp. 21-30 ◽

Cited By ~ 7

Author(s):

Stephan Purr ◽

Josef Meinhardt ◽

Arnulf Lipp ◽

Axel Werner ◽

Martin Ostermair ◽

...

Keyword(s):

Data Mining ◽

Data Acquisition ◽

Data Driven ◽

Quality Analysis ◽

Process Conditions ◽

Data Sets ◽

Body Parts ◽

Car Body ◽

Sample Data ◽

Mining Methods

Data-driven quality evaluation in the stamping process of car body parts is quite promising because dependencies in the process have not yet been sufficiently researched. However, the application of data mining methods for the process in stamping plants would require a large number of sample data sets. Today, acquiring these data represents a major challenge, because the necessary data are inadequately measured, recorded or stored. Thus, the preconditions for the sample data acquisition must first be created before being able to investigate any correlations. In addition, the process conditions change over time due to wear mechanisms. Therefore, the results do not remain valid and a constant data acquisition is required. In this publication, the current situation in stamping plants regarding the process robustness will be first discussed and the need for data-driven methods will be shown. Subsequently, the state of technology regarding the possibility of collecting the sample data sets for quality analysis in producing car body parts will be researched. At the end of this work, an overview will be provided concerning how this data collection was implemented at BMW as well as what kind of potential can be expected.

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