Product property controlled multi-stage hot sheet metal forming

多阶段热金属板材成形能够生产硬化的几何形状复杂的零件。然而，这一过程涉及毛坯和工具之间的时变相互作用，这很难估计，并对热机械历史产生影响。这些相互作用最终会影响所产生的产品属性，因此会受到不必要的波动。为了实现稳健、高效和多功能的生产，本项目旨在通过传感器捕捉多道次板材热成形过程中的相互作用，并采用合适的执行机构技术对其进行补偿，并相应地对产品性能进行闭环控制。在第三阶段中，将在具有扩展致动器技术的级进模中，在近工艺条件下，实现对带一个弯架的冲压硬化帽形异型材不同区域的硬度分布和减薄分布的闭环控制。在此基础上，对所开发的板材多工步热成形性能控制概念进行了验证，并论证了其可移植性。应当指出的是，第三阶段的基本控制概念与第二项目阶段制定的以分级优化为基础的概念相对应，并有各种扩展，目的是适应近过程条件。首先，工具和执行器技术以及所实现的传感器必须满足大批量生产的要求。此外，硬件和软件(软测量、估计器、控制)必须表现出必要的稳健性和实时能力。因此，为了满足上述要求，首先对温度测量进行粗化，并在构件宽度上扩展，然后进行温度和成形建模。此外，还将通过实施热成像相机、3D激光传感器和3MA系统，通过扩展干扰估计和补偿来研究稳健性和精度的提高。为了量化所开发的闭环控制对最终产品性能的改善，将有激活的闭环控制的实验系列的制造部件的产品性能与没有进行主动控制实验的产品性能进行比较。在调查的同时，将从成形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.