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

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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.