Prediction of metal sheet forming based on a geometrical model approach
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Prediction of metal sheet forming based on a geometrical model approach Pascal Froitzheim 1 & Michael Stoltmann 2 & Normen Fuchs 3 & Christoph Woernle 2 & Wilko Flügge 4 Received: 12 June 2019 / Accepted: 3 December 2019 # Springer-Verlag France SAS, part of Springer Nature 2019
Abstract The panel production of small batch sizes for the hull of large ships requires a stable and flexible forming process, which is momentarily manually controlled by a system operator. The manual forming press control includes the metal sheet handling above the forming tool for defining the contact point and engagement depth of the sword and subjective monitoring of the forming degree by using the light gap check method. For objectifying the process monitoring and reducing the dependency on the experience of the system operator an automated solution is needed. Within the automated process control the metal sheet deformation behavior has to be predicted in real-time during the forming process. To achieve this, the deformation prognosis for the ship panel’s production is handled inside the described work. Based on a state of art analysis a geometrical approach to describe the metal sheet deformation behavior is developed for the multi-step forming process by three-point-bending. The related geometrical parameters are predicted using a new type of prediction method by means of an artificial neural network. This prediction method requires the network definition and extensive experimental investigations for training the artificial neural network. Keywords Shipbuilding . Free bending . Forming simulation . Artificial intelligence . Process control . Substitute model
Introduction: Forming metal sheets by free bending The structural design of large ships is based upon the usage of frames to support the ship’s hull, which is composed by individually formed three-dimensional metal sheets with large dimensions and large thicknesses (Fig. 1). The individual shape of the metal sheets and small batch sizes of each shape require a reproducible forming process to * Pascal Froitzheim [email protected] 1
Fraunhofer Research Institution for Large Structures in Production Engineering IGP, Albert-Einstein-Straße 30, 18057 Rostock, Germany
2
Chair of Technical Dynamics, University of Rostock, Justus-von-Liebig-Weg 6, 18055 Rostock, Germany
3
Faculty of Mechanical Engineering, Hochschule Stralsund – University of Applied Sciences, Zur Schwedenschanze 15, 18435 Stralsund, Germany
4
Chair of Production Technology, University of Rostock, Albert-Einstein-Straße 2, 18059 Rostock, Germany
form any possible shape needed. The forming process bases on a manually controlled three-point bending process with a sword and a die as forming tool. The metal sheet is supported by a four-cable crane with individually controllable actuators. The plate is manually positioned above the forming tool by the system operator (Fig. 2a). To get a desired shape the metal sheet is formed within the forming process by engaging the forming sword into the
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