Closed-Loop Control of Sheet Forming Processes: Control Theory and Machine Design

本项目的总体目标是探索采用过程中测量和控制概念的薄板零件柔性成形的概念。其目的是消除长设置和工具开发时间，大大改善传统工具设计的过程，并允许小批量生产复杂的板材零件。这项工作将侧重于变形传递函数概念的细化，以及该概念与柔性成形系统的耦合，该系统是首席研究员在该项目之前所使用的。控制理论工作将集中于在传递函数概念和成形过程中的弹性回弹之间建立更强的理论联系，并将其扩展到聚合物和复合材料。实验工作将在轴对称系统和变构模系统上进行。对变构形成型机本身进行充分的评价，并根据其独特的特点对一些新颖的成形方法进行试验。最后，开发了由新型成形机和变形传递函数成形控制策略组成的完整的形状指令成形系统。

The overall goal of this project is to explore concepts for flexible forming of sheet parts of employing in-process measurement and control concepts. The intent is to eliminate long setup and tooling development times, to greatly improve the process of conventional tooling design and to permit small lot size production of complex sheet parts. The work will focus on refinement of the Deformation Transfer Function concept, and on the coupling of this concept with the flexible forming system that the principal investigator has worked with prior to this project. The control theory work will concentrate on making stronger theoretical connection between the transfer function concept and elastic springback in forming, and on extensions to polymer and composite material. Experimental work will be conducted on the axisymmetric system and on the variable configuration die system. The variable configuration forming machine itself will be fully evaluated, and some novel forming methods based on its unique characteristics will be tested. Finally, a completely integrated shape commanded forming system, comprising the new forming machine and the Deformation Transfer Function forming control strategy will be developed.