Product property controlled multi-stage hot sheet metal forming

多阶段热金属板成形能够生产硬化的几何形状复杂的部件。然而，该过程涉及坯料和工具之间的时变相互作用，这是难以估计的，并且对热机械历史有影响。这些相互作用最终会影响所得产品的性质，因此会出现不期望的波动。为了实现稳健、高效和通用的生产，该项目旨在从感官上捕捉多阶段热金属板成形中的相互作用，用合适的致动器技术对其进行补偿，并相应地对产品性能进行闭环控制。在第三阶段中，在接近工艺条件下，采用扩展致动器技术，在连续模中实现硬度分布的闭环控制，并对带有一个弯曲框架的冲压硬化帽形型材的不同区域进行减薄分布。将验证开发的概念，控制产品性能的多阶段热金属板成形，并证明其可移植性的基础上，这一设置。应该注意的是，第三阶段的基本控制概念对应于第二项目阶段开发的基于分层优化的概念，具有旨在适应近过程条件的各种扩展。首先，刀具和执行器技术以及所安装的传感器必须满足大批量生产的要求。此外，硬件和软件（软传感器，估计器，控制）必须表现出必要的鲁棒性和实时能力。因此，为了满足上述要求，温度测量将首先被鲁棒化，扩展到整个部件宽度，并调整温度和成形建模。此外，将通过扩展的干扰估计和补偿，与实施的热成像相机，三维激光传感器，和3MA系统的鲁棒性和精度的提高进行研究。为了量化开发的闭环控制所产生的产品性能的改善，将从具有激活的闭环控制的实验系列制造的部件的产品性能与没有激活的控制实验进行比较。在调查的同时，将从成型和控制工程的角度确定可转移的设计准则。

Multi-stage hot sheet metal forming enables the production of hardened geometrically complex components. However, this process involves time-varying interactions between the blank and the tools, which are difficult to estimate and have an effect on the thermo-mechanical history. These interactions ultimately influence the resulting product properties, which are therefore subject to undesirable fluctuations. In order to achieve a robust, efficient, and versatile production, this project aims to sensorially capture the interactions in multi-stage hot sheet metal forming, compensate them with suitable actuator technologies, and to closed-loop control the product properties accordingly. In this 3rd phase, the closed-loop control of the hardness distribution coupled with the thinning distribution for different areas of a press-hardened hat-shaped profile with one bent frame will be implemented in a progressive die with extended actuator technology under near-process conditions. The developed concept for controlling the product properties in multi-stage hot sheet metal forming will be validated and its transferability demonstrated based on this setup. It should be noted that the fundamental control concept of the third phase corresponds to the hierarchical optimization-based concept developed in the second project phase, with various extensions aimed at adapting to near-process conditions. Firstly, the tool and actuator technology as well as the implemented sensors must meet the requirements of a high-volume production. Moreover, the hardware and the software (soft sensors, estimators, control) must exhibit the necessary robustness and real-time capability. Therefore, in order to fulfill the mentioned requirements, the temperature measurement will first be robustified, expanded across the component width, and the temperature and forming modeling will be adapted. Additionally, the improvement of robustness and accuracy will be investigated through expanded disturbance estimation and compensation, with the implementation of a thermal imaging camera, a 3D laser sensor, and the 3MA system. To quantify the improvement of the resulting product properties by the developed closed-loop control, the product properties of manufactured components from experimental series with an activated closed-loop control will be compared to those without active control experiments. In parallel with the investigations, transferable design guidelines will be determined from the perspective of forming and control engineering.