Novel concept for measurement of global blank draw-in when deep drawing outer skin automotive components

Abstract

Modern press shops in the automotive industry have to deal with many challenges. One challenge is to achieve a consistent part quality. In order to reach this target, modern press systems and tools are equipped with several types of sensors. For example, there are sensors to measure characteristic values of blanks or sensors to measure the temperature in the tools. Often several sensors are used simultaneously. A significant parameter for determining the quality of draw panels is the draw-in amount. Previously, it was only possible to measure selective points of the draw-in amount due to sensors in the tools. All the known sensors have disadvantages, for example, they are exposed to wearing or susceptible to contamination. In this paper, a sensor system will be introduced that allows the measurement of the global draw-in amount of a drawn panel. Here, the draw-in amount is not measured in the draw die, it is measured during the transportation of the part to the following operation. Within the short transport time the part can be fully covered by an optical system. This leads to a multitude of advantages compared with previously known systems. For example, it is no longer necessary to equip every tool with sensor technology to measure the draw-in amount. Now it is sufficient to equip every press line with a single system to measure the draw-in. This fact leads not only to lower costs, it also simplifies the tool design. In addition, the risk of contamination of the sensor system is greatly reduced. The paper will also introduce an actuator that was built to locally vary the blankholder forces for a sheet metal forming process. Furthermore, an FEM model is presented that allows the determination of the effective range of these actuators. With the knowledge from the FEM simulation, an approach for an open loop control is presented. With this approach, the press shops at Opel are developing a control procedure in order to influence the stamping process positively.