TY - JOUR
T1 - Tooling-integrated sensing systems for stamping process monitoring
AU - Mahayotsanun, Numpon
AU - Sah, Sripati
AU - Cao, Jian
AU - Peshkin, Michael
AU - Gao, Robert X.
AU - Wang, Chuan tao
N1 - Funding Information:
The authors gratefully acknowledge funding provided by the National Science Foundation under CMMI-0620957 and CMMI-0620972.
PY - 2009/6
Y1 - 2009/6
N2 - In-situ stamping process monitoring plays a critical role in enhancing productivity and ensuring part quality in sheet metal stamping. This paper investigates the realization of two sensing methods to create a tooling-integrated sensing system: mutual inductance-based displacement measurement for sheet draw-in, and distributed contact pressure measurement at the tool-workpiece interface. The two sensing systems are complementary in nature, and together, they significantly enhance the on-line observability of the stamping process. The performance of the draw-in sensor was evaluated using numerical simulations and experiments in a small-scale and a large-scale lab setup, and its effectiveness has been confirmed under the presence of wrinkled sheet. To study the spatial and temporal variations of the tool-workpiece contact pressure in a stamping operation, experiments were conducted on a customized panel stamping test-bed with an array of thin-film force sensors embedded below the die flange and die cavity. The force sensor data were then numerically interpolated to form the contact pressure distribution across the tool-workpiece interface, based on the thin plate spline (TPS) method. Comparison between the interpolated pressure obtained from the surface generation techniques and direct measurement using redundant sensors and a press mounted load cell confirms the validity of the new contact pressure sensing method. The integrated sensing technique provides insight into the stamping process by quantifying process variations and providing a reference base for process control to reduce product disparities. Additionally, new product and process designs can be created based on the quantified and referenced variations.
AB - In-situ stamping process monitoring plays a critical role in enhancing productivity and ensuring part quality in sheet metal stamping. This paper investigates the realization of two sensing methods to create a tooling-integrated sensing system: mutual inductance-based displacement measurement for sheet draw-in, and distributed contact pressure measurement at the tool-workpiece interface. The two sensing systems are complementary in nature, and together, they significantly enhance the on-line observability of the stamping process. The performance of the draw-in sensor was evaluated using numerical simulations and experiments in a small-scale and a large-scale lab setup, and its effectiveness has been confirmed under the presence of wrinkled sheet. To study the spatial and temporal variations of the tool-workpiece contact pressure in a stamping operation, experiments were conducted on a customized panel stamping test-bed with an array of thin-film force sensors embedded below the die flange and die cavity. The force sensor data were then numerically interpolated to form the contact pressure distribution across the tool-workpiece interface, based on the thin plate spline (TPS) method. Comparison between the interpolated pressure obtained from the surface generation techniques and direct measurement using redundant sensors and a press mounted load cell confirms the validity of the new contact pressure sensing method. The integrated sensing technique provides insight into the stamping process by quantifying process variations and providing a reference base for process control to reduce product disparities. Additionally, new product and process designs can be created based on the quantified and referenced variations.
KW - Draw-in sensing
KW - Embedded pressure sensing
KW - Stamping process monitoring
KW - TPS surfaces
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U2 - 10.1016/j.ijmachtools.2009.01.009
DO - 10.1016/j.ijmachtools.2009.01.009
M3 - Article
AN - SCOPUS:64349104726
VL - 49
SP - 634
EP - 644
JO - International Journal of Machine Tool Design & Research
JF - International Journal of Machine Tool Design & Research
SN - 0890-6955
IS - 7-8
ER -