Virtual Design and Adaptive Control of Metal Spinning Processes
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Date
2018-06
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Doctoral Thesis
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Abstract
Metal spinning is classified as an incremental sheet metal forming process and as such features some unique advantages over conventional stamping operations. Their elevated number of degrees of freedom provides great flexibility on one hand, but is cumbersome to translate into standardized procedures on the other. Thus the design of the process layout is a challenging task, which is usually carried out manually by experienced personnel, based on a trial-and-error approach.FEM and meta-modelling are widely used state of the art methodologies for process analysis and optimization, but the application of these on metal spinning is very limited. Due to its highly dynamic and localised forming character, accurate modelling of the process relies on full scale 3D models. In combination with the comparably long process cycles, this mostly results in restrictive computational times, making classical virtual optimization infeasible.This works aims to discover systematic methodologies, which enable automated tool path design for metal spinning processes. In order to do this, the finite element method is employed and optimized in terms of computational time and resources. Based on the models, extensive insight on the deformation characteristics and the failure modes is provided. Subsequently, different concepts for automated tool path design are proposed. These are a closed loop control system, which is integrated into the models, enabling constrained and failure free tool path design, and a simplified model, which approximates the results of the adaptive control strategy, but is not bound to any computational effort.The functionality of the concepts for automated tool path design is verified on two different test geometries and materials. For proof of concept the results are validated with metal spinning tests, in which the computed paths have been applied via CNC machine, demonstrating that the developed methodologies indeed enable failure free production of components. A detailed comparison shows that these generally surpass the manual design in aspect of quality and cycle time.
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published
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Examiner : Hora, Pavel
Examiner : van den Boogaard, Ton
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ETH Zurich
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Subject
Incremental sheet forming; Metal spinning; FEM Simulation
Organisational unit
03685 - Hora, Pavel (emeritus) / Hora, Pavel (emeritus)
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Is cited by: http://hdl.handle.net/20.500.11850/108231
Has part: https://doi.org/10.3929/ethz-b-000118155
Has part: https://doi.org/10.3929/ethz-b-000205766
Has part: https://doi.org/10.3929/ethz-b-000242786