Flexible manufacturing chain with integrated incremental bending and Q-P heat treatment for on-demand production of AHSS safety parts

Frohn-Sörensen, Peter; Mašek, Bohuslav; Wagner, Martin F.-X.; Rubešová, Kateřina; Khalaj, Omid; Engel, Bernd

doi:10.1016/j.jmatprotec.2019.116312

Cited by 19 publications

(9 citation statements)

References 23 publications

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“…FROHN-SÖRENSEN et al introduce a flexible manufacturing chain for an incremental bending process, where individualization is achieved by the variation of different profile shapes for the same forming tool [6]. Including the customer's individual anthropometry, SCHILLER et al process a freeform bending method, where an individualized chair is manufactured automatically according to the body measurements of the customer [7].…”

Section: Introductionmentioning

confidence: 99%

3D printed prototyping tools for flexible sheet metal drawing

Frohn-Sörensen

Geueke

Tuli

et al. 2021

Int J Adv Manuf Technol

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Due to the change from mass production to mass personalized production and the resulting intrinsic product flexibility, the automotive industry, among others, is looking for cost-efficient and resource-saving production methods to combining global just-in-time production. In addition to geometric manufacturing flexibility, additive manufacturing offers a resource-saving application for rapid prototyping and small series in predevelopment. In this study, the FDM process is utilized to manufacture the tooling to draw a small series of sheet metal parts in combination with the rubber pad forming process. Therefore, a variety of common AM polymer materials (PETG, PLA, and ABS) is compared in compression tests, from which PLA is selected to be applied as sheet metal forming die. For the rubber pad forming process, relevant processing parameters, i.e., press force and rubber cushion hardness, are studied with respect to forming depth. The product batch is examined by optical evaluation using a metrological system. The scans of the tool and sheet metal parts confirm the mechanical integrity of the additively manufactured die from polymer and thus the suitability of this approach for small series in sheet metal drawing processes, e.g., for automotive applications.

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Section: Introductionmentioning

confidence: 99%

3D printed prototyping tools for flexible sheet metal drawing

Frohn-Sörensen

Geueke

Tuli

et al. 2021

Int J Adv Manuf Technol

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“…In forming technology, the forming tools play a key role as the link between semifinished products and machines and directly impact the flexibility of a forming process [2]. To be more precise, kinematic forming processes such as three-rollpush bending [3] or incremental swivel bending [11] have inherent flexibility due to their shape-giving tool movement. In contrast, tool-bound processes like stamping are limited regarding an achievable variety of geometries.…”

Section: Introductionmentioning

confidence: 99%

Towards CAD-Based Mathematical Optimization for Additive Manufacturing – Designing Forming Tools for Tool-Bound Bending

Reintjes

Reuter

Hartisch

et al. 2021

Lecture Notes in Mechanical Engineering

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The trend towards flexible, agile, and resource-efficient production systems requires a continuous development of processes as well as of tools in the area of forming technology. To create load-adjusted and weight-optimized tool structures, we present an overview of a new algorithm-driven design optimization workflow based on mixed-integer linear programming. Loads and boundary conditions for the mathematical optimization are taken from numerical simulations. They are transformed into time-independent point loads generating physical uncertainty in the parameters of the optimization model. CAD-based mathematical optimization is used for topology optimization and geometry generation of the truss-like structure. Finite element simulations are performed to validate the structural strength and to optimize the shape of lattice nodes to reduce mechanical stress peaks. Our algorithm-driven design optimization workflow takes full advantage of the geometrical freedom of additive manufacturing by considering geometry-based manufacturing constraints. Depending on the additive manufacturing process, we use lower and upper bounds on the diameter of the members of a truss and the associated yield strengths. An additively manufactured flexible blank holder demonstrates the algorithm-driven topology design optimization.

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“…This, however, requires a deep understanding of the forming zone and strategies to control the overlapping deformation zones [12]. Incremental methods, such as Incremental Swivel Bending (ISB), can be utilized for in-plane bending of blanks and open profiles to achieve a high degree of forming flexibility [13,14]. In ISB the bending moment is transmitted by clamping units which frictionally engage tensile or compressive loads in longitudinal direction to the semi-finished product.…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Influencing the forming zone by altering the contact pressure in a bending process

Frohn-Sörensen¹,

Reuter²,

Engel³

2021

Esaform 2021

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In a modern production environment, flexible manufacturing methods are important because an overall trend towards mass customization and on-demand production is observed. Kinematic and incremental forming methods with generic tools can provide a large product variation but a deeper understanding of the forming mechanisms is required for process modelling, e.g. Incremental Swivel Bending (ISB). Particularly crucial is to identify the influences on the forming zone in order to purposefully control the material flow of a forming process. For a bending process where the bending moment is transmitted by clamping tools, this paper presents a method to alter the contact pressure distribution in order to affect the angular size and strain gradient of the forming zone. In the light of these results, the presented method can be deployed for a tooling with adaptive contact pressure to directly influence material flow, in particular using generic tools to overall provide a better control of flexible forming methods.

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Flexible manufacturing chain with integrated incremental bending and Q-P heat treatment for on-demand production of AHSS safety parts

Cited by 19 publications

References 23 publications

3D printed prototyping tools for flexible sheet metal drawing

3D printed prototyping tools for flexible sheet metal drawing

Towards CAD-Based Mathematical Optimization for Additive Manufacturing – Designing Forming Tools for Tool-Bound Bending

Influencing the forming zone by altering the contact pressure in a bending process

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