Measuring Systems for Sheet-Bulk Metal Forming

2015 ◽  
Vol 639 ◽  
pp. 291-298 ◽  
Author(s):  
Andreas Loderer ◽  
Martin Timmermann ◽  
Steffen Matthias ◽  
Markus Kästner ◽  
Thomas Schneider ◽  
...  
Keyword(s):  
Metal Forming ◽  
Measuring System ◽  
Fringe Projection ◽  
Measuring Systems ◽  
Projection System ◽  
Bulk Metal ◽  
Surface Parameters ◽  
Bulk Metal Forming ◽  
Optical Measuring ◽  
Forming Tools

In order to fulfil today’s demands on fast, efficient and sustainable production processes the sheet-bulk metal forming is being developed as a new forming technology within the scope of the SFB/Transregio 73. Characteristically for the sheet bulk metal forming is a three dimensional material flow, which allows for extensive freedom in the design process. To ensure maintaining all the advantages, provided by sheet-bulk metal forming, new inspection concepts for the produced parts as well as for the forming tools have to be developed. For a production-related inspection of produced parts a multi-sensor fringe projection system is under development, which will be employed to detect deviations of features’ form and size. With its sensors of varying measuring range and resolution a feature adapted inspection is possible. Additionally an optical fibre sensor is projected to detect small parts of interest in a very high resolution to enhance the possibilities of the multiscale multi-sensor system. A newly developed endoscopic fringe projection system is used to inspect parts that are out of reach for common optical measuring systems such as the forming tool of the process. This allows for a continuous measurement of tool features and thus the detection of slow growing wear. Challenging for measurement tasks in the sheet-bulk metal forming process are not only the complex geometries but also the harsh environmental conditions and especially for the parts’ inspection, the different surface parameters. In this article the surface parameters of the some sheet-bulk metal formed parts and forming tools will be explained, followed by a description of the different measuring systems. Finally an exemplary evaluation of the influence of the surface properties on an optical measuring system will be shown.

Machines and Tools for Sheet-Bulk Metal Forming

2011 ◽  
Vol 473 ◽  
pp. 91-98 ◽  
Author(s):  
Marion Merklein ◽  
A. Erman Tekkaya ◽  
Alexander Brosius ◽  
Simon Opel ◽  
Lukas Kwiatkowski ◽  
...  
Keyword(s):  
Metal Forming ◽  
Incremental Forming ◽  
Batch Size ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
New Process ◽  
Novel Approaches ◽  
The Individual ◽  
Forming Tools ◽  
Functional Components

The demand on closely-tolerated and complex functional components in the automotive sector, like e.g. synchronizer rings, leads to the development of a new process-class named “sheet-bulk metal forming”. Within this technology bulk metal forming operations are applied on sheet metals. In the following two novel approaches considering machines and tools for sheet-bulk metal forming are presented. The first approach aims on a technology based on rolling, which is suitable for mass production. The second one is an incremental forming solution for low batch production. Both machine concepts allow the application of different forming strategies to manufacture individual tailored semi-finished products in term of a pre-distribution of material. These products feature variable sheet thicknesses and mechanical properties, which can be adapted to their case of applica-tion. Depending on the individual batch size, the blanks can be finished to functional parts by sub-sequent forming processes like deep drawing and upsetting, extrusion or incremental forming. In this paper the case of an incremental tooth-forming is mainly considered. Forming sequences and resulting loads are modeled and calculated by finite elements simulations for all discussed processes to serve as a basis for the design and dimensioning of the machine components and forming tools.

Experimental and numerical analysis of tribological effective surfaces for forming tools in Sheet-Bulk Metal Forming

2016 ◽  
Vol 10 (1) ◽  
pp. 37-50 ◽  
Author(s):  
Petra Kersting ◽  
Daniel Gröbel ◽  
Marion Merklein ◽  
Peter Sieczkarek ◽  
Sebastian Wernicke ◽  
...  
Keyword(s):  
Numerical Analysis ◽  
Metal Forming ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Forming Tools

Holistic Measurement in the Sheet-Bulk Metal Forming Process with Fringe Projection

2012 ◽  
Vol 504-506 ◽  
pp. 1005-1010 ◽  
Author(s):  
Christoph Ohrt ◽  
Wito Hartmann ◽  
Johannes Weickmann ◽  
Markus Kästner ◽  
Albert Weckenmann ◽  
...  
Keyword(s):  
Metal Forming ◽  
Optical Measurement ◽  
Fringe Projection ◽  
Small Scale ◽  
Work Piece ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Deviation Analysis ◽  
Metal Forming Process

Sheet bulk metal forming is a new forming technology, currently developed by several companies and research institutes. It creates high demands on the inspection of parts and tools, especially in the field of in-situ abrasion detection of the forming tool and its impacts on the work piece. This manuscript introduces two optical testing methods for fulfilling these inspection tasks: On the one hand the endoscopic fringe projection as a flexible small scale optical measurement principal with high depth of focus and accuracy for the acquisition of filigree form elements for a continuous abrasion determination and one the other hand the multi-scaled fringe projection for a holistic one shot measurement of the work piece for an adapted, multiscale deviation analysis. The development and advantages of both systems for the sheet bulk metal forming process are shown as well as potentials of the combination of the both systems close to the proposed application next to the production line.

Maturity Determination of New Forming Processes Considering Uncertain Indicator Values

2012 ◽  
Vol 502 ◽  
pp. 97-102 ◽  
Author(s):  
Albert Weckenmann ◽  
Goekhan Akkasoglu
Keyword(s):  
Metal Forming ◽  
Information Uncertainty ◽  
Strategic Decisions ◽  
Early Maturity ◽  
Bulk Metal ◽  
Development Status ◽  
Bulk Metal Forming ◽  
Maturity Assessment ◽  
Comprehensive Development ◽  
Forming Tools

The development of new forming processes primarily aims for increasing the process robustness and shortening the process chain. With the development of the novel Sheet-Bulk Metal Forming, cause-effect relationships are to be parameterized optimally and the economic efficiency of the manufacturing process is to be improved. The extensive and comprehensive development tasks often lead to an intransparent development status. Hence, operational and strategic decisions - particularly in the early development stages - are often made on the basis of subjective criteria and a high information uncertainty. This often results in wrong decisions as well as subsequent cost-intensive modifications in the design of expensive forming tools and forming machines. Based on a designed maturity method relevant indicators for the early maturity assessment and thus cost-reduced improvement of the development status of new forming processes are defined in this paper. The maturity here reflects the phase dependent development status. By providing a uniform basis of maturity indicators a comparable evaluation of the development status becomes enabled. The validity of the maturity assessment is enhanced by considering the information uncertainty by use of Fuzzy Logic. An exemplary maturity determination is performed within the development of the Sheet-Bulk Metal Forming.

scholarly journals Fringe Projection Profilometry in Production Metrology: A Multi-Scale Comparison in Sheet-Bulk Metal Forming

Sensors ◽  
2021 ◽  
Vol 21 (7) ◽  
pp. 2389
Author(s):  
Lennart Hinz ◽  
Sebastian Metzner ◽  
Philipp Müller ◽  
Robert Schulte ◽  
Hans-Bernward Besserer ◽  
...  
Keyword(s):  
Metal Forming ◽  
Fringe Projection ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Precise Knowledge ◽  
Production Metrology ◽  
3D Scanners ◽  
Improve Production Technology ◽  
Correct Application ◽  
Fringe Projection Profilometry

Fringe projection profilometry in combination with other optical measuring technologies has established itself over the last decades as an essential complement to conventional, tactile measuring devices. The non-contact, holistic reconstruction of complex geometries within fractions of a second in conjunction with the lightweight and transportable sensor design open up many fields of application in production metrology. Furthermore, triangulation-based measuring principles feature good scalability, which has led to 3D scanners for various scale ranges. Innovative and modern production processes, such as sheet-bulk metal forming, thus, utilize fringe projection profilometry in many respects to monitor the process, quantify possible wear and improve production technology. Therefore, it is essential to identify the appropriate 3D scanner for each application and to properly evaluate the acquired data. Through precise knowledge of the measurement volume and the relative uncertainty with respect to the specimen and scanner position, adapted measurement strategies and integrated production concepts can be realized. Although there are extensive industrial standards and guidelines for the quantification of sensor performance, evaluation and tolerancing is mainly global and can, therefore, neither provide assistance in the correct, application-specific positioning and alignment of the sensor nor reflect the local characteristics within the measuring volume. Therefore, this article compares fringe projection systems across various scale ranges by positioning and scanning a calibrated sphere in a high resolution grid.

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