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Sheet metal forming in the era of industry 4.0: using data and simulations to improve understanding, predictability and performance
Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering. (Product Development Research Laboratory)ORCID iD: 0000-0002-8601-6825
2019 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

A major issue within automotive Sheet Metal Forming (SMF) concerns ensuring desired output product quality and consistent process performance. This is fueled by complex physical phenomena, process fluctuations and complicated parameter correlations governing the dynamics of the production processes. The aim of the thesis is to provide a deeper understanding of the challenges and opportunities in this regard within automotive SMF. The research is conducted in collaboration with a global automotive manufacturer. 

The research shows that systematic investigations using process simulation models allow exploration of the product-process parameter interdependencies and their influence on the output product quality. Furthermore, it is shown that incorporating in-line measured data within process simulation models enhance model prediction accuracy. In this regard, automating the data processing and model configuration tasks reduces the overall modelling effort.

However, utilization of results from process simulations within a production line requires real-time computational performance. The research hence proposes the use of reduced process models derived from process simulations in combination with production data, i.e. a hybrid data- and model-based approach. Such a hybrid approach would benefit process performance by capturing the deviations present in the real process while also incorporating the enhanced process knowledge derived from process simulations. Bringing monitoring and control realms within the production process to interact synergistically would facilitate the realization of such a hybrid approach.

The thesis presents a procedure for exploring the causal relationship between the product-process parameters and their influence on output product quality in addition to proposing an automated approach to process and configure in-line measured data for incorporation within process simulations. Furthermore, a framework for enhancing output product quality within automotive SMF is proposed. Based on the thesis findings, it can be concluded that in-line measured data combined with process simulations hold the potential to unveil the convoluted interplay of process parameters on the output product quality parameters.

Place, publisher, year, edition, pages
Karlskrona: Blekinge Tekniska Högskola, 2019.
Series
Blekinge Institute of Technology Licentiate Dissertation Series, ISSN 1650-2140 ; 18
Keywords [en]
Modelling, Simulation, Industry 4.0, Sheet Metal Forming, Process Monitoring, Process Control, Automation, Finite Element Analysis, Smart Manufacturing, Mechanical Engineering
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:bth-18954ISBN: 978-91-7295-394-9 (print)OAI: oai:DiVA.org:bth-18954DiVA, id: diva2:1372742
Presentation
2019-12-20, J1610, Blekinge Institute of technology, Karlskrona, 13:00 (English)
Opponent
Supervisors
Projects
Model Driven Development and Decision Support
Funder
Knowledge Foundation
Note

Related work:

1) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-14412

2) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-14388

3) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-18935

Available from: 2019-11-25 Created: 2019-11-25 Last updated: 2019-12-18Bibliographically approved
List of papers
1. Introductory study of sheet metal forming simulations to evaluate process robustness
Open this publication in new window or tab >>Introductory study of sheet metal forming simulations to evaluate process robustness
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2018 (English)In: IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing (IOPP), 2018, Vol. 418, article id 012111Conference paper, Published paper (Refereed)
Abstract [en]

The ability to control quality of a part is gaining increased importance with desires to achieve zero-defect manufacturing. Two significant factors affecting process robustness in production of deep drawn automotive parts are variations in material properties of the blanks and the tribology conditions of the process. It is imperative to understand how these factors influence the forming process in order to control the quality of a formed part. This paper presents a preliminary investigation on the front door inner of a Volvo XC90 using a simulation-based approach. The simulations investigate how variation of material and lubrication properties affect the numerical predictions of part quality. To create a realistic lubrication profile in simulations, data of pre-lube lubrication amount, which is measured from the blanking line, is used. Friction models with localized friction conditions are created using TriboForm and is incorporated into the simulations. Finally, the Autoform-Sigmaplus software module is used to create and vary parameters related to material and lubrication properties within a user defined range. On comparing and analysing the numerical investigation results, it is observed that a correlation between the lubrication profile and the predicted part quality exists. However, variation in material properties seems to have a low influence on the predicted part quality. The paper concludes by discussing the relevance of such investigations for improved part quality and proposing suggestions for future work.

Place, publisher, year, edition, pages
Institute of Physics Publishing (IOPP), 2018
Series
IOP Conference Series: Materials Science and Engineering, ISSN 1757-8981
Keywords
Sheet Metal Forming, Friction Modelling, Process Robustness, Zero Defect Manufacturing, Industry 4.0, Digitization, Production Engineering.
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:bth-16613 (URN)10.1088/1757-899X/418/1/012111 (DOI)
Conference
37th IDDRG Conference - Forming of High Performance Sheet Materials and Components, Waterloo, Canada.
Projects
Model Driven Development and Decision Support
Funder
Knowledge Foundation
Note

open access

Available from: 2018-06-23 Created: 2018-06-23 Last updated: 2019-11-25Bibliographically approved
2. Data-driven modelling in the era of Industry 4.0: A case study of friction modelling in sheet metal forming simulations
Open this publication in new window or tab >>Data-driven modelling in the era of Industry 4.0: A case study of friction modelling in sheet metal forming simulations
2018 (English)In: Journal of Physics: Conference Series 1063 (2018) 012135, Institute of Physics Publishing (IOPP), 2018, Vol. 1063Conference paper, Published paper (Refereed)
Abstract [en]

With growing demands on quality of produced parts, concepts like zero-defect manufacturing are gaining increasing importance. As one of the means to achieve this, industries strive to attain the ability to control product/process parameters through connected manufacturing technologies and model-based control systems that utilize process/machine data for predicting optimum system conditions without human intervention. Present work demonstrates an automated approach to process in-line measured data of tribology conditions and incorporate it within sheet metal forming (SMF) simulations to enhance the prediction accuracy while reducing overall modelling effort. The automated procedure is realized using a client-server model with an in-house developed application as the server and numerical computing platform/commercial CAD software as clients. Firstly, the server launches the computing platform for processing measured data from the production line. Based on this analysis, the client then executes CAD software for modifying the blank model thereby enabling assignment of localized friction conditions. Finally, the modified blank geometry and accompanied friction values is incorporated into SMF simulations. The presented procedure reduces time required for setting up SMF simulations as well as improves the prediction accuracy. In addition to outlining suggestions for future work, paper concludes by discussing the importance of the presented procedure and its significance in the context of Industry 4.0.

Place, publisher, year, edition, pages
Institute of Physics Publishing (IOPP), 2018
Keywords
Sheet Metal Forming, Friction Modelling, Automation, Zero Defect Manufacturing, Industry 4.0, Digitization, Data Analytics, Production Engineering.
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:bth-16841 (URN)10.1088/1742-6596/1063/1/012135 (DOI)
Conference
NUMISHEET 2018, Tokyo, Japan
Projects
MD3S – Model Driven Development and Decision Support
Funder
Knowledge Foundation
Note

Open access

Available from: 2018-08-08 Created: 2018-08-08 Last updated: 2020-02-26Bibliographically approved
3. A hybrid data- and model-based approach to process monitoring and control in sheet metal forming
Open this publication in new window or tab >>A hybrid data- and model-based approach to process monitoring and control in sheet metal forming
2020 (English)In: Processes, ISSN 2227-9717, Vol. 8, no 1, article id 89Article in journal (Other academic) Published
Abstract [en]

The ability to predict and control the outcome of the sheet metal forming process demands holistic knowledge of the product/process parameter influences and their contribution in shaping the output product quality. Recent improvements in the ability to harvest in-line production data and the increased capability to understand complex process behaviour through computer simulations open up the possibility for new approaches to monitor and control production process performance and output product quality. This research presents an overview of the common process monitoring and control approaches while highlighting their limitations in handling the dynamics of the sheet metal forming process. The current paper envisions the need for a collaborative monitoring and control system for enhancing production process performance. Such a system must incorporate comprehensive knowledge regarding process behaviour and parameter influences in addition to the current-system-state derived using in-line production data to function effectively. Accordingly, a framework for monitoring and control within automotive sheet metal forming is proposed. The framework addresses the current limitations through the use of real-time production data and reduced process models. Lastly, the significance of the presented framework in transitioning to the digital manufacturing paradigm is reflected upon.

Place, publisher, year, edition, pages
MDPI, 2020
Keywords
in-line measurement data; modelling and simulation; product quality; process performance; process monitoring and control; Industry 4.0; sheet metal forming
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:bth-19038 (URN)10.3390/pr8010089 (DOI)000516825300077 ()
Projects
MD3S – Model Driven Development and Decision Support
Funder
Knowledge FoundationSwedish Agency for Economic and Regional GrowthEuropean Regional Development Fund (ERDF)
Note

Publisher's link: https://www.mdpi.com/2227-9717/8/1/89

Available from: 2019-12-18 Created: 2019-12-18 Last updated: 2020-04-02Bibliographically approved

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