A draw-in sensor for process control and optimization

Numpon Mahayotsanun, Jian Cao*, Michael Peshkin

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

3 Scopus citations

Abstract

Sheet metal forming is one of the major processes in manufacturing and is broadly used due to its high degree of design flexibility and low cost. In the sheet metal forming process, draw-in (planar movement of a sheet periphery) frequently occurs and is one of the most dominated indicators on the success of a forming process. Currently, monitoring and controlling draw-in during each stamping operation requires either time-consuming setup or a significant die modification. Most devices have been used only in laboratory settings. Our goal is to design a draw-in sensor providing high sensitivity in monitoring; ease of setup, measurement and controlling; and eventually be implemented in industry. Our design is based on the mutual inductance principle, which we considered physical factors affecting the characteristics of the draw-in sensor. Two different configurations, single-transducer and double-transducer of our draw-in sensors have been designed and tested. The results showed good linearity, especially for the double-transducer case. The output of the draw-in sensor was affected by the type of sheet metal, dimension of the transducer, and the distance between the transducer and the testing sheet metal. It was found that the result was insensitive to the waviness of the sheet metal if sheet thickness was thin. The invention, implementation, and integration of the draw-in sensor will have an enormous impact on revolutionizing the control of stamping process, will provide solid ground for process variation and uncertainty studies, and ultimately will affect the design decision process.

Original languageEnglish (US)
Title of host publicationNUMISHEET 2005
Subtitle of host publicationProceedings of the 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes
PublisherAmerican Institute of Physics Inc.
Pages861-866
Number of pages6
ISBN (Print)0735402655, 9780735402652
DOIs
StatePublished - Aug 5 2005
EventNUMISHEET 2005: 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes - Detroit, MI, United States
Duration: Aug 15 2005Aug 19 2005

Publication series

NameAIP Conference Proceedings
Volume778 A
ISSN (Print)0094-243X
ISSN (Electronic)1551-7616

Other

OtherNUMISHEET 2005: 6th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes
CountryUnited States
CityDetroit, MI
Period8/15/058/19/05

ASJC Scopus subject areas

  • Physics and Astronomy(all)

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