Manufacturing of combined convex-concave form elements by using active-medium support in incremental sheet forming

Project: Research

Project participants

Description

Incremental sheet forming (ISF) is a manufacturing process, which has a high flexibility and is suitable for producing small lot sizes. However, without solid support beneath the blank, for example through a die or a counter tool, complex geometries with a good geometrical accuracy cannot be formed.
The first funding period of the research project on incremental sheet forming with active medium (IFAM) met this challenge by providing a soft support through a liquid or gaseous medium on the blank’s underside. The combination of tool path and pressure level enabled both the manufacturing of convex and concave elements as well as combined convex-concave parts. One aspect of the first funding period was analysing the convex bulging behaviour by including
analytical, experimental and numerical methods. To achieve a target geometry accurately, the intricate correlations between the process parameters and the part shape had to be considered and led to an interdisciplinary collaboration with the field of machine learning. A neural network was trained to predict the required pressure in an online closed-loop control of the geometrical properties. Compared to the manufacturing process with constant pressure, the geometrical
accuracy was significantly improved by using a dynamically adjusted pressure level.
Beside the great potential of this controlling concept, it has the disadvantage of being restricted to one specific material and one predetermined geometry. The motivation behind the second funding period is to solve this problem and extend the applicability of the controlling concept to any arbitrary material and geometry. The extended controlling concept is based on the research hypothesis that a strong relationship between target shape, forming energy and tangential forming forces exists and can be expressed by a mathematical equation. The analytical model, which includes the aforementioned mathematical equation, was proven by numerical results as preliminary work to this project proposal. In this approach, the pressure level of the medium as a pivotal correcting variable was replaced by the tangential forces and thus requires further investigation of the interrelation between the process parameters. To ensure that the extended
controlling concept includes all dependencies, the multidisciplinary cooperation with the field of machine learning is necessary. The underlying goal of this cooperation is to develop an online closed-loop control for a reliable and a reproducible manufacturing process. The controlled forming process will be completed by design guidelines, which include the processing of CAD-
files and the compensation of geometric deviations through adapting manufacturing sequences of combined convex-concave parts and tool paths
StatusFinished
Period01.04.2330.09.24

Research outputs

Recently viewed

Publications

  1. What motivates people to use energy feedback systems? A multiple goal approach to predict long-term usage behaviour in daily life
  2. Folgekonzepte für den Weiterbetrieb von landwirtschaftlichen Biogasanlagen - Eine Betrachtung aus Betreiber- und Bankenperspektive
  3. Nationales und internationales Nachtragsmanagement, Kooperation und Schiedsgutachtervereinbarungenm, Neue Entwicklungen im Baurecht
  4. Diversity-enhanced canopy space occupation and leaf functional diversity jointly promote overyielding in tropical tree communities
  5. Integrating inductive and deductive analysis to identify and characterize archetypical social-ecological systems and their changes
  6. Effekte von mündlichen versus schriftlichen Antwortformaten bei der performanznahen Messung von Deutsch-als-Zweitsprache (DaZ)-Kompetenz
  7. Langzeiteffekte eines Online-Trainings zur Reduktion von depressiven Beschwerden für Personen mit Diabetes Mellitus Typ 1 und Typ 2
  8. The impact of national and international debate in the European Union on the moratorium on the release of GMO into the environment
  9. Cultural Diversity Management - Handlungsempfehlungen für Rekrutierung, Entwicklung und Bindung von Personen mit Migrationshintergrund
  10. "Außerschulische politische Jugendbildung und politische Erwachsenenbildung – wie geht es weiter?" Dokumentation einer Zukunftswerkstatt
  11. Earnings less risk-free interest charge (ERIC) and stock returns: ERIC’s relative and incremental information content in a European sample
  12. Comparison of PSA-specific CD8+ CTL responses and antitumor immunity generated by plasmid DNA vaccines encoding PSA-HSP chimeric proteins
  13. Disentangling associations of human wellbeing with green infrastructure, degree of urbanity, and social factors around an Asian megacity
  14. Wie entfalten Reallabore Wirkung für die Transformation? Eine embedded-agency perspective zur Analyse von Wirkmechanismen in Reallaboren
  15. Resilient Privacy Preservation Through a Presumed Secrecy Mechanism for Mobility and Localization in Intelligent Transportation Systems
  16. Performance-oriented measurement of teachers’ competence in linguistically responsive teaching, relevant learning opportunities and beliefs
  17. It’s (not) the winning – The Special Olympics national handball teams in the trade-off between desire for sporting success and social support
  18. Exploring the potential of SMEs to build individual, organizational, and community resilience through sustainability-oriented business practices
  19. Efficient Consumer Response : Supply Chain Management (SCM), Category Management (CM) und Radiofrequenz-Identifikation (RFID) als neue Strategieansätze
  20. Phasen- und institutionenübergreifend studieren – Konzeption und Evaluation eines Seminars zur Förderung schriftsystematischer Professionalität
  21. Kosten-Effektivitäts-Analyse eines Online Programmes zur Reduktion von depressiven Beschwerden bei Personen mit Diabetes mellitus Typ 1 und Typ 2