Calmano, Stefan ; Schmitt, Sebastian O. ; Groche, Peter (2013):
Prevention of over-dimensioning in light-weight structures by control of uncertainties during production.
pp. 313-317, Stuttgart, MAT INFO Werkstoff-Informationsgesellschaft mbH, Proceedings of the International Conference on “New Developments in Forging Technology”, [Conference or Workshop Item]

Abstract

A load adapted dimensioning of constructive parts is aspired in order to achieve the goal of lightweight-design motivated material reduction. To prevent oversizing, uncertainties in product properties, like geometry and strength, which are caused by fluctuating properties of semi-finished parts, must be controlled 1. Narrow tolerances in semi-finished part specification lead to an increase in costs and testing effort. The alternative approach is to control uncertainties by a feedback or adaptive control system. Therefore, several flexible and adaptive forming processes are designed and evaluated. As an example, a bending process for the flexible production of a heat dissipater shows, that geometric properties like the bending angle can be achieved reproducibly, despite material and sheet-thickness related spring-back. The process is conducted on the 3D Servo Press, a novel servo press with 3 degrees of freedom of the ram. It consists of an implemented material and sheet thickness detection and thus can adapt to actual semi-finished part properties 2. This approach is to be transferred to forging processes in the future. By using the three degrees of freedom of the 3D Servo Press, the potential to influence incremental processes, like rotary forging of thick-walled tubes or billets, is under evaluation.

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