Enhanced Semi-Analytical Process Simulation of Air Bending

Ridane, N.; Jaksic, D.; Kleiner, Matthias; Heller, B.

doi:10.4028/0-87849-972-5.729

Cited by 2 publications

(1 citation statement)

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“…In order to determine the deflection of the machine and to quantify its influence on the bending process, experimental investigations were carried out on a conventional CNC press brake at the IUL [3,4]. From the data gained in these experiments, important quantities such as the stiffness of the Cframe and the stiffness of the press brake ram could be extracted.…”

Section: Advanced Materials Research Vols 6-8mentioning

confidence: 99%

Enhanced Semi-Analytical Process Simulation of Air Bending

Ridane

Jaksic

Kleiner³

et al. 2005

AMR

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The air bending process is one of the most widely used process for the manufacturing of sheet metal bending parts made of thin as well as of thick sheet metal. Although the air bending process offers a very high production potential due to its great flexibility, it is associated with certain problems which can negatively influence the shape and dimensional accuracy of the bending parts. Examples for such negative influences are the springback of the material, the batch variations, or the deflections of the bending machine and tools. These differences have to be considered either in the determination of the process parameters or they have to be compensated later on in the manufacturing process itself. A well established approach to calculate process data for forming processes is the use of a process simulation. At the Institute of Forming Technology and Lightweight Construction (IUL) a simulation software called Sheet Metal Bending Simulation (SMBS) has been developed and successfully been tested for the field of sheet metal bending, based on semi-analytical approaches. Although it already provides very satisfactory results in general, disturbances such as material and batch variations as well as the deflections of C-frame, machine table, and press brake ram can still negatively affect the prediction of the punch displacement necessary to achieve a certain bend angle. While material and batch variations cannot properly be considered in a process simulation at present, the afore mentioned influences offer a promising potential for improvements. Therefore, in order to further improve the accuracy of predicted quantities such as punch displacement and bending angle, a new module describing the elastic machine behaviour of press brakes has been developed and successfully been integrated in the process simulation SMBS. Experimental investigations have been carried out on a conventional CNC press brake to verify the efficiency of the newly implemented approach.

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Section: Advanced Materials Research Vols 6-8mentioning

confidence: 99%

Enhanced Semi-Analytical Process Simulation of Air Bending

Ridane

Jaksic

Kleiner³

et al. 2005

AMR

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A Self-Correcting Approach for the Bending of Metal Parts

Damerow

Borzykh

Homberg

et al. 2012

KEM

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During the manufacture of metal parts, geometrical deviations can appear. The reasons for this can be a variation in the properties of the semi-finished product, or wear phenomena on the punch-bending machine itself or on the punch-bending tool. When geometrical deviations appear, the process parameters normally have to be adjusted manually. The choice of the most appropriate process parameters is currently based on the operator's experience. Unfortunately, this is a time-consuming and expensive procedure right at the early stages of a production scenario. In addition, the trend towards reduced part sizes with tight tolerances, made of high strength materials, is drastically increasing the requirements regarding the production process. In order to reduce the scrap rate and the setup time for production scenarios, it is necessary to implement corrective action during the process by means of a special control strategy. A self-correcting control strategy based on a closed-loop control approach is thus under development at the University of Paderborn. The first step in this strategy involved conducting simulations is to identify those process variables, e.g. the strength or the geometrical properties of the material, which have a significant influence on the process. Once correlations between input and output variables had been established, different self-correcting control strategies were set up. To validate the simulation and to test the quality of the self-correcting control strategies, a special experimental tool, mapping the most important bending operations, was constructed at the University of Paderborn. The experimental tool is equipped with an additional measurement device and can be operated on a universal testing machine. Finally, the self-correcting control strategies were tested under production conditions on the original tool in order to take any additional influences of the punch-bending machine into consideration. In this paper, recent investigations are presented that were conducted in a collaborative project at the University of Paderborn together with two industrial partners. The results of the correlation between the variables governing the process, the development of a suitable measurement method, and a first approach to a self-correcting control strategy are set out.

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Enhanced Semi-Analytical Process Simulation of Air Bending

Cited by 2 publications

References 0 publications

Enhanced Semi-Analytical Process Simulation of Air Bending

Enhanced Semi-Analytical Process Simulation of Air Bending

A Self-Correcting Approach for the Bending of Metal Parts

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