This article addresses process, stamping, and manufacturing engineers, as well as tool designers (prototype and series production tools), and press shop planners in the range of metal forming. The paper deals with methods of modelling and simulating the metal forming process and their application in product design, production, and forming process planning. In models usually applied major effects on the forming process are neglected. For instance, the elastic behaviour of presses and die tools is not considered in process and tool planning. Thus, reworking of tools is a consequence of this model oversimplification. The paper illustrates how interactions between forming press, die tool and metal forming processes can be modelled by enhancing conventional FE models. Several examples demonstrate the information value of the Advanced Forming Process Model (AFPM).Keywords: simulation of forming process, digital simulation of behaviour, virtual press, advanced forming process model, AFPM
This paper presents a brief introduction to competition-driven digital transformation in the machining sector. On this basis, the creation of a digital twin for machining processes is approached firstly using a basic digital twin structure. The latter is sub-grouped into information and data models, specific calculation and process models, all seen from an application-oriented perspective. Moreover, digital shadow and digital twin are embedded in this framework, being discussed in the context of a state-of-the-art literature review. The main part of this paper addresses models for machine and path inaccuracies, material removal and tool engagement, cutting force, process stability, thermal behavior, workpiece and surface properties. Furthermore, these models are superimposed towards an integral digital twin. In addition, the overall context is expanded towards an integral software architecture of a digital twin providing information system. The information system, in turn, ties in with existing forward-oriented planning from operational practice, leading to a significant expansion of the initially presented basic structure for a digital twin. Consequently, a time-stratified data layer platform is introduced to prepare for the resulting shadow-twin transformation loop. Finally, subtasks are defined to assure functional interfaces, model integrability and feedback measures.
Deep drawing of paperboard with rigid tools and immediate compression has only a small presence in the market for secondary packaging solutions due to a lack of understanding of the physical relations that occur during the forming process. As with other processes that deal with interactions between two solids in contact, the control of the factors that affect friction is important due to friction’s impact on runnability and process reliability. A new friction measurement device was developed to evaluate the factors influencing the friction behavior of paperboard such as under the specific conditions of the deep drawing process, which differ from the standard friction testing methods. The tribocharging of the contacting surfaces, generated during sliding friction, was determined to be a major influence on the dynamic coefficient of friction between paperboard and metal. The same effect could be examined during the deep drawing process. With increased contact temperature due to the heating of the tools, the coefficient of friction decreased significantly, but it remained constant after reaching a certain charging state after several repetitions. Consequently, to avoid ruptures of the wall during the forming process, tools that are in contact with the paperboard should be heated.
The scientific paper proposes a method to analyze and optimize the drawing press and the deep drawing process with a virtual model. It focuses on hydraulic multi-point die cushions since they offer a wide range of possible adjustments and a high potential to increase production quality and efficiency. The operator can apply individual die cushion cylinder forces to the blankholder which enables the control of the forming process and manual die spotting can theoretically be reduced to a minimum. Utilizing the virtual model can improve the drawing press’ behavior and significantly reduce the set-up time for drawing presses during try-out of new tools or when tool sets are transferred to a different machine. The paper presents a system simulation model of a deep drawing press including its mechanics, hydraulics, and control. It serves as a basis for developing an advanced control system which improves system performance with potentially higher slide speeds, and therefore, a more efficient production. Another aspect in the paper is the development of a coupled simulation consisting of the machine model and a process model. This includes the elasto-static as well as the dynamic behavior of the drawing press and allows for simulations with the highest possible level of detail. The model was used to determine individual set forces for the die cushion cylinders which allowed for the production of sound quality parts without manual die spotting.
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