Development of a geometry-based method for compensation of process-induced dimensional deviations of massive formed components

为解决这一问题，提出了一种用于大型金属成形零件生产的刀侧系统偏差的数值补偿策略，从而生成了模具几何形状与锻件之间的映射函数。根据所需的最终几何形状，借助此映射函数，可以计算出调整后的模具几何形状。这种纯粹的几何方法考虑了与偏差有关的系统影响的整体。在CAD环境中，将为零件设计所谓的控制点，这充分描述了几何形状。通过比较DAC环境中控制点和锻造零件上控制点的位置，可以得出零件的形状变形(零件中的几何变化)。为此，可以使用实验数据和数值数据。在此形状变形的基础上，将开发一种数值偏差补偿策略。为了为CAD几何图形生成各自的映射函数，将使用基于离散曲面描述的偏差补偿。该算法的实现将以通用的CAD格式进行。由于离散曲面重构中基于控制点位移的CAD几何形状变形可以直接传递到模具几何上，因此不再需要为实现模具和零件几何而进行容易出错和昂贵的曲面重建。

The design of bulk metal forming processes in the industrial practice bases on trial and error tests, which is inefficient due to the time and cost aspect.For solving this problem within this project a numerical strategy for compensation of tool-side systematically deviations for the production of bulk metal formed parts will be developed.Therefore a mapping function between the used die geometry and the respective forged parts will be generated. Based on the required final geometry with the help of this mapping function am adjusted die geometry can be calculated. This purely geometrically approach takes into account the entirety of systematical effects regarding deviations.In the CAD environment so called control points will be designed for a part, which describe the geometry sufficiently. A comparison of the positions of the control points in the DAC environment and at the forged parts allows deriving a shape morphing of the part (geometrical changes in the part). For this, experimental as well as numerical data can be used.Based on this shape morphing a numerical deviation compensation strategy will be developed. To generate a respective mapping function for the CAD geometry, deviation compensation based on the discrete surface description will be used. The implementation of the algorithm will be carried out in a general CAD format. Error-prone and expensive surface-reconstructions for the actualization of the die- and part-geometries are not needed anymore, because of the geometry-update from the shape morphing of the CAD-geometry based on the displacement of the control points in the discrete surface reconstruction, which can be transferred directly on the die-geometry.