Press Tool Parameter Setting for Blank Property Variation
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Solution Overview
Problem
The transition from toolmaking to series production often results in component shape or quality discrepancies due to differences in material properties between trial and series blanks, leading to significant time and effort in adjusting tooling and causing potential downtimes and increased costs.
Innovation Solution
A method to determine and adjust the operating parameters of a tool in a press by acquiring semifinished product properties of blanks, calculating mean values, selecting blanks within a specified interval, forming components, and iteratively adjusting the operating parameters to achieve desired quality, thereby ensuring consistent blank quality and minimizing adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If trial blanks with general specifications are used for toolmaking, then tool development can proceed, but component shape and quality do not correspond when transitioning to series production
Solution Approach 1:
The system performs preliminary characterization of series production blanks during toolmaking, acquiring semifinished product properties before the tool is finalized. This preliminary action enables prediction of series production results and adjustment of tool parameters in advance, preventing discrepancies when transitioning to series production.
Solution Approach 2:
The system uses a feedback mechanism where component quality data from series production is fed back to adjust tool parameters. The system determines quality deviations and uses this information to iteratively optimize tool parameters, ensuring that toolmaking results match series production outcomes.
2Manufacturing precision
If tool parameters are adjusted to achieve desired shaping results in series production, then component quality improves, but significant time and work effort are spent
Solution Approach 1:
The system replaces manual trial-and-error adjustment with an automated computational system. A computing device automatically determines optimal tool parameters by analyzing semifinished product properties and predicting their influence on component quality, eliminating time-consuming manual adjustments while maintaining high component quality.
Solution Approach 2:
The system systematically varies tool parameters based on acquired semifinished product properties to find optimal settings. By changing parameters such as forming forces, speeds, and temperatures based on material characteristics, the system achieves desired component quality without extensive trial-and-error time investment.
3Adaptability or versatility
If general specification blanks are used, then material availability is good, but material property variations cause quality deviations
Solution Approach 1:
The system applies local quality by characterizing specific batches of blanks with acquired semifinished product properties rather than treating all blanks uniformly. This allows the system to account for local variations in material properties within general specifications and adjust tool parameters accordingly to maintain consistent component quality.
Solution Approach 2:
The system adapts tool parameters based on the specific semifinished product properties of each blank batch. By changing parameters such as forming temperature, pressure, and speed according to measured material characteristics, the system compensates for material property variations while maintaining quality consistency across different batches.
Data Source
AI summary
A method for determining an operating parameter of a tool for forming components in a press, comprising the steps of: gathering a semifinished product property for a specified number of blanks from a set comprising a plurality of blanks; ascertaining a mean of the semifinished product property for the specified number of blanks; selecting at least one blank, the semifinished product property of which lies in a specified interval around the mean, from the set; forming the selected blank by means of the tool in the press to produce the component, the tool being operated with the operating parameter; determining a deviation of the component shape of the component from a target value; and, adjusting or maintaining the at least one operating parameter in accordance with the determined deviation.