CAE Tools as Valid Opportunity to Improve Quality Control Systems Performances for Sheet Metal Formed Components

2008 ◽  
Author(s):  
Antonio Del Prete ◽  
Teresa Primo ◽  
Alfredo Elia
Keyword(s):  
Quality Control ◽  
Control System ◽  
Sheet Metal ◽  
Process Simulation ◽  
A Priori ◽  
Test System ◽  
Forming Process ◽  
Forming Simulation ◽  
On Line ◽  
Simulation Results

The numerical simulation of the forming process is a consolidated technique to verify, a priori, the effectiveness of the designed “method” to realize components obtained by sheet metal forming. As it is used in the industrial field at present, the limit of the forming simulation is that simulation results are based on an initial hypothesis that isn’t really true, that is on the hypothesis that the forming process is deterministic. Facts prove such affirmation is wrong considering that each input variable/datum of the simulation is non-deterministic by definition [1]. Therefore, a more realistic approach that uses the process simulation should consider this uncertainty by treating the process parameters as uncertain in an admissible domain. The authors are, at the moment, engaged in the development of an on line control and test system based on acquisition modules composed by a laser and two CCD video cameras. Its aim is to allow the statistical monitoring of the forming process through the investigation of the produced parts, and to point out, with a sufficient confidence level, situations of incipient process drift. The sampling frequency is 1, 2 parts per minute depending on the part main dimensions, therefore an express loading system of the part has been designed without clamps adoption [2]. The support provided by the non-deterministic simulation to the on line control system is very important. In fact, in the first phase of the production screening, for each produced part it allows to verify the areas that have a higher “risk” of defect on the basis of the simulation results. Moreover, as well as the simulation supplies useful suggestions on the areas of each piece at top priority where the quality control is executed, the quality control system can also provide interesting information for the non-deterministic process simulation system, thanks to the data and the measurements carried out on line, in order to increase the numerical-experimental correlation of the designed control system.

Auto-Body Panel Springback Analysis Using Yoshida-Uemori Model

2011 ◽  
Vol 314-316 ◽  
pp. 815-818 ◽  
Author(s):  
Kang Kang Hu ◽  
Xiong Qi Peng ◽  
Jun Chen ◽  
Hong Sheng Lu ◽  
Jian Zhang
Keyword(s):  
Sheet Metal ◽  
Process Simulation ◽  
Anisotropic Material ◽  
Material Behavior ◽  
Forming Process ◽  
Material Models ◽  
Forming Simulation ◽  
Automobile Body ◽  
Springback Prediction ◽  
Body Panel

The forming process simulation and springback prediction of an automobile body panel is implemented by using JSTAMP/LS-DYNA. Yoshida-Uemori model is selected to characterize the anisotropic material behavior of sheet metal during forming. Simulation predictions on spingback are compared with experiment measurements along with numerical results from other material models to demonstrate the effectiveness and accuracy of the Yoshida-Uemori model.

scholarly journals The Effect of Swinging Ball Heads with Different Arrangements in Multi-Point Stretch-Forming Process

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 337 ◽  
Author(s):  
Jian Xing ◽  
Yan-yan Cheng ◽  
Zhuo Yi
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Sheet Metal ◽  
Strain Distribution ◽  
Finite Element Models ◽  
Stretch Forming ◽  
Forming Process ◽  
Forming Quality ◽  
Staggered Arrangement ◽  
Simulation Results

To improve the effect of multi-point stretch forming of sheet metal, it is proposed in this paper to replace a fixed ball head with a swinging ball head. According to the multi-point dies with different arrangements, this research establishes finite element models of the following stretch forming, i.e., fixed ball heads with conventional arrangement, swinging ball heads with conventional arrangement, swinging ball heads with declining staggered arrangement, and swinging ball heads with parallel staggered arrangement, and then numerical simulation is performed. The simulation results show that by replacing a fixed ball head with a swinging ball head, the surface indentation of the part formed was effectively suppressed, the stress and tension strain distribution of the part formed was improved, and the forming quality was improved; the thickness of the elastic pad was reduced, the springback was reduced and the forming accuracy was improved; and when the ball head was applied to a multi-point die with staggered arrangement, a better forming result was achieved, where the best forming result was achieved in combining the swinging ball heads with the multi-point die with a parallel staggered arrangement. Forming experiments were carried out, and the experimental results were consistent with the trend of numerical simulation results, which verified the correctness of the numerical simulation.

3D Loading Path-Generating Method for FEM Simulation of Incremental Sheet Metal Forming Process

2010 ◽  
Vol 97-101 ◽  
pp. 2810-2815 ◽  
Author(s):  
Yan Xu ◽  
Shuang Gao Li ◽  
Lin Gao
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Fem Simulation ◽  
Loading Path ◽  
Forming Process ◽  
Forming Simulation ◽  
Generating Method ◽  
Incremental Sheet Metal Forming ◽  
3D Loading

Incremental forming of sheet metal is difficult to be simulated for its complicated 3D loading path. In this work, an acceptable approach to generate 3D loading path, called “virtual guiding model method” is accomplished. The method, which has the similar idea with the conventional copy mill, is based on FEM and the basic principle of kinematics. With the help of the method, multi-stage incremental forming of a drawing typed square cup was simulated in the FEM software-PAMSTAMP and experimented. Through measuring the thickness distribution the vertical edge of the cup, the most difference between them is less than 0.05mm, which is satisfied with engineering request, and the results shows that the 3D loading path generating method is one of the most effective way to realize the incremental forming simulation.

Research on the Key Technologies of Intelligent Control for Cap-Shape Bending of Sheet Metal

2011 ◽  
Vol 239-242 ◽  
pp. 2867-2872
Author(s):  
Hong Lei Sun ◽  
Chun Jian Su ◽  
Rui Xue Zhai
Keyword(s):  
Neural Network ◽  
Control System ◽  
Real Time ◽  
Sheet Metal ◽  
Intelligent Control ◽  
Feed Forward Neural Network ◽  
Forming Process ◽  
Intelligent Control System ◽  
The Neural Network ◽  
Real Time Identification

The blueprint for an intelligent control system of cap-shape bending has been advanced in this paper using neural network technology, aiming at an accurate control of bending springback, the prominent problem during the forming process for the cap-shape bending of sheet metal. The feed-forward neural network of real-time identification for material performance parameters and the friction coefficient have been established. The neural network identifies the parameters for real-time needed material performance, which utilizes the measurability of the physical quantities, and predicts the parameters for optimum technology, so a satisfied accuracy of convergence has been achieved. The intelligent control experimentation system of cap-shape bending has been established, the validity of which has been tested for four kinds of materials. The result of the tests proves the feasibility of the blueprint of the intelligent control system.

Forming Stability Analysis of Surface Flexible Rolling

2013 ◽  
Vol 798-799 ◽  
pp. 267-271
Author(s):  
Ren Jun Li ◽  
Ming Zhe Li ◽  
Zhong Yi Cai
Keyword(s):  
Numerical Simulation ◽  
Stability Analysis ◽  
Sheet Metal ◽  
Three Dimensional ◽  
Continuous Manufacturing ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flexible Rolling ◽  
Simulation Results

Surface flexible rolling method, using two integral working rolls as the forming tool, can achieve fast, flexible and continuous manufacturing of three-dimensional sheet metal parts. This paper introduces the basic principle of surface flexible rolling and discusses the numerical simulation results when the working rolls are bended as circular arcs. The stability indicates the forming effect to some extent and the flow type of the metal can be deduced from stability analysis. To integrate and analyze the simulation results by means of reverse engineering. The analysis results show that the forming process is stable and the effect of surface flexible rolling is fine. It also indicates that inhomogeneous deformation and accumulation occurs during the process. The numerical simulation and experimental results demonstrate that the surface flexible rolling is a feasible and effective way to form three-dimensional sheet metal parts.

scholarly journals Bat Algorithm Based an Adaptive PID Controller Design for Buck Converter Model

2020 ◽  
Vol 26 (7) ◽  
pp. 62-82
Author(s):  
Luay Thamir Rasheed
Keyword(s):  
Control System ◽  
Optimization Algorithm ◽  
Pid Controller ◽  
Tracking Error ◽  
Bat Algorithm ◽  
Input Voltage ◽  
Buck Converter ◽  
Control Action ◽  
On Line ◽  
Simulation Results

The aim of this paper is to design a PID controller based on an on-line tuning bat optimization algorithm for the step-down DC/DC buck converter system which is used in the battery operation of the mobile applications. In this paper, the bat optimization algorithm has been utilized to obtain the optimal parameters of the PID controller as a simple and fast on-line tuning technique to get the best control action for the system. The simulation results using (Matlab Package) show the robustness and the effectiveness of the proposed control system in terms of obtaining a suitable voltage control action as a smooth and unsaturated state of the buck converter input voltage of ( ) volt that will stabilize the buck converter system performance. The simulation results show also that the proposed control system when compared with the other controllers results has the capability of minimizing the rising time to (  sec) and the settling time to (  sec) in the transient response and minimizing the voltage tracking error of the system output to ( ) volt at the steady state response. Furthermore, the number of fitness evaluations is decreased.

Implantation of an On-Line Quality Control System for the Glucose Meters of the Health Area From the Virgen Macarena University Hospital

2008 ◽  
Vol 7 (3) ◽  
pp. 159
Author(s):  
M. S. Rodríguez Oliva ◽  
C. Sánchez Mora ◽  
M. Carrascosa-Salmoral ◽  
M. F. Fernández Gallardo ◽  
V. Sánchez Margalet ◽  
...  
Keyword(s):  
Quality Control ◽  
Control System ◽  
Quality Control System ◽  
University Hospital ◽  
Health Area ◽  
On Line

Study on the Spring-Back Effect with Stress Distribution According to Forming Sheet Width in the Roll Forming Process

2015 ◽  
Vol 789-790 ◽  
pp. 116-120
Author(s):  
Dong Hong Kim ◽  
Hao Yu ◽  
Dong Won Jung
Keyword(s):  
Stress Distribution ◽  
Roll Forming ◽  
Spring Back ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Simulation ◽  
Sheet Width ◽  
Simulation Results ◽  
The Relationship ◽  
Roll Forming Process

This study, based on finite element analysis, analyzed the spring back phenomenon and stress distribution of forming sheets (HTS) in the roll forming process. By comparison of the stress distribution, this study analyzed two kinds of simulation. The first simulation performed simple bending simulation before roll forming simulation. With reference to the first simulation results, the second simulation analyzed the relationship between the stress distribution and the phenomenon of spring back. We also studied the stress distribution effect for spring back in the forming sheet.

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