Forming and Fabricating Machine Tools and Accessories

292 Pages·2004·4.91 MB·English

Technology Assessment
for
Forming and Fabricating
Machine Tools and Accessories
AMT – The Association For Manufacturing Technology
July 2002
Published by:
AMT - The Association For Manufacturing Technology
7901 Westpark Drive, McLean, VA 22102
Printed in the United States of America
Copyright (cid:148) 2002 AMT - The Association For Manufacturing Technology all
rights reserved. No part of this publication may be reproduced in any form, in an
electronic retrieval system or otherwise, without prior written permission of the
publisher.
ii
FOREWORD
This document has been prepared for AMT – The Association For Manufacturing
Technology by the Engineering Research Center for Net Shape Manufacturing
(ERC/NSM) at Ohio State University1. This Center was established on May 1,
1986 and works with companies interested in advanced manufacturing research.
The focus of the ERC/NSM is net shape manufacturing with emphasis on cost-
effective production of discrete parts. The research concentrates on
manufacturing from engineering materials to finish or near-finish dimensions via
processes that use dies and molds. In addition to conducting industrially relevant
engineering research on a contractual basis for interested companies, the
ERC/NSM has the objectives to a) establish close cooperation between industry
and the university, b) train students, and c) transfer the research results to
interested companies.
This report entitled “TECHNOLOGY ASSESSMENT FOR FORMING AND
FABRICATING MACHINE TOOLS AND ACCESSORIES” identifies new
developments, customer/user requirements, relevant and practice oriented R&D
activities related to the metal forming machinery industry. A literature review was
conducted using U.S., German, and Japanese resources. The scope of the study
focused on the following points a) metal forming and fabricating machine tools, b)
dies and tools for metal forming, c) software for process modeling, die design
and manufacture, and d) new materials for advanced forming applications. The
emphasis of the study was placed on R&D related topics.
1 Information about the ERC/NSM can be obtained from the office of the Director, Taylan
Altan, located at 339 Baker Systems Engineering Building, 1971 Neil Avenue,
Columbus, Ohio 43210-1271, phone: (614) 292-9267, fax: (614) 292-7219, email:
[email protected], web page: http://www.ercnsm.org. This report is Report No.
ERC/NSM-01-40
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Contributors to this report include:
(cid:120)(cid:3) Patrick Wenning, Graduate Research Associate
(cid:120)(cid:3) Hariharasudhan Palaniswamy, Graduate Research Associate
(cid:120)(cid:3) Prashant Soman, Graduate Research Associate
(cid:120)(cid:3) Mark Gariety, Graduate Research Associate
(cid:120)(cid:3) Taylan Altan, Professor and Director
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TECHNOLOGY ASSESSMENT FOR FORMING AND
FABRICATING MACHINE TOOLS AND ACCESSORIES
EXECUTIVE SUMMARY
The ERC/NSM has completed a technology assessment on forming and
fabricating machine tools and accessories for AMT - The Association For
Manufacturing Technology. The scope of the study focused on the following
points:
(cid:120)(cid:3) Metal forming and fabricating machine tools (Bending Machines, Forming
Cells and Systems, Hot and Cold Forming Machines, Presses, Press
Brakes and Shears and Special Purpose Forming Equipment).
(cid:120)(cid:3) Dies and tools for metal forming.
(cid:120)(cid:3) Software for process modeling, die design and manufacture.
(cid:120)(cid:3) New materials for advanced forming applications.
(cid:120)(cid:3) Worldwide survey with emphasis on U.S., Germany and Japan.
The emphasis was placed on R&D related activities. Thus, information that is
easily available in company brochures, web sites and trade shows was not
covered. In conducting this study we relied heavily on personal contacts with
individuals in universities (especially in Germany).
The study was conducted as follows:
(cid:120)(cid:3) Review of relevant technical literature from the U.S., Germany and Japan.
(cid:120)(cid:3) Contact selected high technology oriented companies, world wide, that
manufacture metal forming equipment.
(cid:120)(cid:3) Contact selected European research laboratories and universities that
work closely with industry.
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The objectives of this work are:
(cid:120)(cid:3) Identify new developments, customer/user requirements, relevant and
practice oriented R&D activities related to the metal forming machinery
industry.
(cid:120)(cid:3) Assess the significance and relevance of the identified activities and
trends for manufacturers of metal forming equipment and accessories.
Chapter 1 of this report gives recent developments in Sheet and Tube Forming
Machines and Tooling. Sheet bending and shearing, blanking and forming cells,
progressive die blanking and forming, stamping and transfer die forming, sheet
hydroforming, and tube forming are all discussed. Research work for machines,
tools, and process variations for the aforementioned categories is included.
Chapter 2 discusses recent developments in Billet and Rod Forming Machines
and Tooling. Wire and rod drawing, forming and shearing, cold and warm forging
and extrusion, and hot forging and extrusion are all discussed. Research work for
machines, tools, and process variations for the aforementioned categories is
included.
Chapter 3 provides recent research on advanced forming applications for new
materials such as high strength steels, aluminum and magnesium.
Chapter 4 gives practical examples of the Finite Element Method used in
industrial applications. Research results for FEM modeling of sheet forming, tube
hydroforming, and forging are discussed.
Chapter 5 describes research efforts for Other Supporting Technologies in metal
forming (e.g. tool coatings, process monitoring and control, and prototyping and
rapid tooling).
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TABLE OF CONTENTS
FOREWORD .......................................................................................................iii
EXECUTIVE SUMMARY......................................................................................v
TABLE OF CONTENTS......................................................................................vii
LIST OF FIGURES...........................................................................................xxv
1. Sheet and Tube Forming Machines and Tooling...........................................1
1.1 Sheet Bending and Shearing..................................................................1
1.1.1 Machines.........................................................................................1
1.1.1.1 Otsu, M., Fujii, M., Osakada, K., (1999) “Three-Dimensional
Laser Bending of Sheet Metal” Proceedings of 6th ICTP, Vol. II, pp. 1025-
1030. .................................................................................................1
1.1.1.2 Arnet, H., (1999) “Section Bending with Kinematic Shaping”
Proceedings of 6th ICTP, Vol. III, pp. 2349-2354........................................2
1.1.1.3 Harrer, O., Lu, J., Schwenzfeier, W., Fischer, F., (1999)
”Asymmetric Rolling” Proceedings of 6th ICTP, Vol. III, pp. 1885-1890......3
1.1.1.4 “Roll Forming of Parts with Variable Sections along the Length
(Research)” Prof. P. Groche / PtU – Institute for Production Technology
and Forming Machines...............................................................................4
1.1.2 Tools................................................................................................5
1.1.2.1 “Development of Tooling and Process for Hemming of
Aluminum Sheet (Ongoing Research)” Prof. K. Siegert / IFU – Institute for
Metal Forming, Technical University Stuttgart, Germany...........................5
1.1.2.2 Ogawa, H., Makinouchi, A., (1999) “Small Radius Bending of
Sheet Metal by Indentation with V-shape Punch” Proceedings of 6th ICTP,
Vol. II, pp. 1059-1064.................................................................................5
1.1.2.3 Kleiner, M. and Wellendorf, A. (2000), “CNC-Two Roll Round
Bending,” LFU – University of Dortmund, Annual Report, pp. 31 (ongoing
research). .................................................................................................6
1.1.2.4 Aomura, S., Koguchi, A., (2002) “Optimized bending
sequences of sheet metal bending by robot” Robotics and Computer-
Integrated Manufacturing, Vol. 18, pp. 29-39.............................................7
1.1.2.5 Yang, M., Manabe, K., Nishimura, H., (1998) “Development of
an intelligent tool system for flexible L-bending process of metal sheets”
Smart Materials and Structures, Vol. 7, pp. 530-536..................................8
1.1.2.6 Elkins, K., Sturges, R., (2001) “Design of a sensor for on-line
measurement of loaded bend angle for pressbrake control” Robotics and
Computer-Integrated Manufacturing, Vol. 17, pp. 329-340........................8
1.1.2.7 “Laser-assisted roll forming (Research)” Prof. M. Geiger –
Institute for Manufacturing Science, University of Erlangen-Nuremberg,
Germany. .................................................................................................9
1.1.3 Process Variations...........................................................................9
1.1.3.1 Hua, M., Baines, K., Cole, I., (1999) “Continuous four-roll plate
bending: a production process for the manufacture of single seamed tubes
of large and medium diameters” International Journal of Machine Tools
and Manufacture, Vol. 39, pp. 905-935......................................................9
vii
1.1.3.2 Otsu, M., Wada, T., Osakada, K., (2001) “Micro-bending of thin
spring by laser forming and spark forming” Annals of the CIRP, Vol.
50/1/2001, pp. 141-144..............................................................................9
1.2 Blanking and Forming Cells..................................................................10
1.2.1 Machines.......................................................................................10
1.2.2 Tools..............................................................................................10
1.2.2.1 Li, W., Yao, Y., Lawrence, (2001) “Laser Forming with
Constant Line Energy” International Journal of Advanced Manufacturing
Technology, Vol. 17, pp. 196-203. ...........................................................10
1.2.2.2 Li, L., (2000) “The advances and characteristics of high-power
diode laser materials processing” Optics and Lasers in Engineering, Vol.
34, pp. 231-253........................................................................................11
1.2.3 Process Variations.........................................................................11
1.3 Progressive Die Blanking and Forming ................................................11
1.3.1 Machines.......................................................................................11
1.3.1.1 Tso, P., Liang, K., (2002) “A nine-bar linkage for mechanical
forming presses” International Journal of Machine Tools and Manufacture,
Vol. 42, pp. 139-145.................................................................................11
1.3.1.2 “Innovative Press Concept for the Manufacture of Precision
Microcomponents (Research)” Prof. P. Groche / PtU – Institute for
Production Technology and Forming Machines, Technical University
Darmstadt, Germany................................................................................12
1.3.1.3 “Investigation of the Dynamic Behavior of Linear Guides in
Forming Presses (Research)” Prof. P. Groche / PtU – Institute for
Production Technology and Forming Machines, Technical University
Darmstadt, Germany................................................................................12
1.3.1.4 Doege, E., Schaprian, M., Derenthal, M., Menz, R., Zacharov,
A., Elend, L., Hubner, S., Barnert, L., Huskic, A., Abdelfattah, S., (2002)
“Practice Oriented Developments at IFUM – Eccentric press with non-
round gear drive” (in German) Proceedings of 17th UKH, Hannover, pp.
63-100. ...............................................................................................13
1.3.1.5 Volbers, Th., (2002) “Flexible Drives of an Eccentric Shaft –
Programmable Drives Control the Slide Velocity of Mechanical Presses”
(in German) Proceedings of 17th UKH, Hannover, pp. 119-128...............14
1.3.1.6 Nakagawa, T., Higuchi, T., Sato, R., (1999) “Linear motor drive
CNC press using learning control” Annals of the CIRP, Vol. 48/1/1999, pp.
199-202. ...............................................................................................15
1.3.2 Tools..............................................................................................18
1.3.2.1 Murakawa, M., Mo, J., Wakatsuki, Y., Koga, N., (2001)
“Investigation of blanking noise reduction using a hydraulic inertia damper”
Journal of Materials Processing Technology, Vol. 112, pp. 205-213........18
1.3.2.2 Haller, D., (2000) “Controllable Nitrogen Gas Spring Systems
for Stamping Applications” New Developments in Sheet Metal Forming,
Institute for Metal Forming Technology of the University of Stuttgart,
Germany, pp. 249-276.............................................................................18
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1.3.2.3 Kocov, A., Lazarev, J., (1999) “A New Approach in Die Set’s
Design” Proceedings of 6th ICTP, Vol. I, pp. 719-722...............................22
1.3.2.4 “Controllable Nitrogen and Hydraulic Cylinder Systems for
Deep Drawing (Research)” Prof. K. Siegert / IFU – Institute for Metal
Forming, Technical University Stuttgart, Germany...................................23
1.3.2.5 Siegert, Haller, (2001) “Controllable Nitrogen Gas Spring
Systems” WGP Production Engineering, Germany, Vol. VIII/1, pp. 63-66...
...............................................................................................23
1.3.2.6 Altan, T., (2000) “Improving progressive stamping die design
with simulations”, STAMPING Journal, September/October 2000, pp. 98-
99. ...............................................................................................25
1.3.3 Process Variations.........................................................................27
1.3.3.1 Schweitzer, M., Hoffmann, H., (1999) “Rotary Blanking”
Proceedings of 6th ICTP, Vol. III, pp. 2219-2224......................................27
1.3.3.2 Knaupp, M., Schulte-Beckhausen, J., (2001) “The Applications
and Limitations of Water Jet Cutting for the Trimming of Single and
Double-Walled Parts” Hydroforming of Tubes, Extrusions and Sheet
Metals, Institute for Metal Forming Technology of the University of
Stuttgart, Germany, pp. 439-454..............................................................28
1.3.3.3 Joo, B., Oh, S., Jeon, B., (2001) “Development of micro
punching system” Annals of the CIRP, Vol. 50/1/2001, pp. 191-194........31
1.3.3.4 Doege, E., Schaprian, M., Derenthal, M., Menz, R., Zacharov,
A., Elend, L., Hubner, S., Barnert, L., Huskic, A., Abdelfattah, S., (2002)
“Practice Oriented Developments at IFUM – The controllable straightening
system” (in German) Proceedings of 17th UKH, Hannover, pp. 63-100....32
1.4 Stamping and Transfer Die Forming.....................................................33
1.4.1 Machines.......................................................................................33
1.4.1.1 Hinderer, U., (2000) “Press Shop Concepts for the Future”
New Developments in Sheet Metal Forming, Institute for Metal Forming
Technology of the University of Stuttgart, Germany, pp. 19-38................33
1.4.1.2 “Hydraulic Deep Drawing Press with CNC Controlled 10-Point
Cushion (Research)” Prof. K. Siegert / IFU – Institute for Metal Forming,
Technical University Stuttgart, Germany..................................................34
1.4.1.3 Konnerth, U., (2001) “A hydraulic high-speed tryout press for
the simulation of mechanical forming processes” Journal of Materials
Processing Technology, Vol. 111, pp. 159-163........................................35
1.4.1.4 Voelkner, W., (2000) “Present and future developments of
metal forming: selected examples” Journal of Materials Processing
Technology, Vol. 106, pp. 236-242..........................................................36
1.4.1.5 Siegert, K., Häussermann, M., Haller, D., Wagner, S., Ziegler,
M., (2000) “Tendencies in presses and dies for sheet metal forming
processes” Journal of Materials Processing Technology, Vol. 98, pp. 259-
264. ...............................................................................................37
1.4.1.6 VanderZee, A., (2000) “Transfer Presses with Electronic Feed”
New Developments in Sheet Metal Forming, Institute for Metal Forming
Technology of the University of Stuttgart, Germany, pp. 67-76................40
ix
1.4.1.7 Kurzinger, F., (2000) “New Concepts for Hydraulic Production
Presses” New Developments in Sheet Metal Forming, Institute for Metal
Forming Technology of the University of Stuttgart, Germany, pp. 77-92..42
1.4.1.8 Walkinshaw, S., Hashimoto, M., (2000) “New Multi-Action
Press for Panel Manufacturer” New Developments in Sheet Metal
Forming, Institute for Metal Forming Technology of the University of
Stuttgart, Germany, pp. 93-100................................................................45
1.4.1.9 Neugebauer, R., Pabler, T., Droos, J., (2000) “Tryout Press –
Requirements, Aspects of Design and Prototype” New Developments in
Sheet Metal Forming, Institute for Metal Forming Technology of the
University of Stuttgart, Germany, pp. 101-118.........................................47
1.4.1.10 Dingle, M., Hodgson, P., Cardew-Hall, M., (2001) “Analysis of
the Elastic Behavior of the Press System” Innovations in Processing and
Manufacturing of Sheet Materials, pp. 405-414........................................47
1.4.1.11 Neugebauer, R. and Putz, M. (2000), “Innovation in Light
Structures for Body and Drive Train,” Proceedings of the Conference on
“Lightweight Construction by Forming Technology,” October 2000,
Chemnitz, pp. 43-68.................................................................................49
1.4.1.12 Tentrine, J. “Press Installations for the Light Construction in
Automotive Body Parts Manufacturing,” Proceedings of the Conference on
“Lightweight Construction by Forming Technology,” October 2000,
Chemnitz, pp. 287-305.............................................................................49
1.4.1.13 Grill, H. "What is Important is the Proper Tilt", Schuler
News/inside - Issue 2. 2001, p. 10...........................................................51
1.4.1.14 Kochan, A., (2001) “Dieless forming” Assembly Automation,
Vol. 21, pp. 321-323.................................................................................52
1.4.2 Tools..............................................................................................53
1.4.2.1 “Vibrating Blank Holder in Deep Drawing (Ongoing Research)”
Prof. K. Siegert / IFU – Institute for Metal Forming, Technical University
Stuttgart, Germany...................................................................................53
1.4.2.2 “Control of Blank Holder Force to Reduce Wrinkling in Deep
Drawing (Ongoing Research)” Prof. K. Siegert / IFU – Institute for Metal
Forming, Technical University Stuttgart, Germany...................................54
1.4.2.3 “Optimum Design of Stamping Dies (Research)” Prof. K.
Siegert / IFU – Institute for Metal Forming, Technical University Stuttgart,
Germany. ...............................................................................................54
1.4.2.4 “Forming of Tailored Blanks (Research)” Prof. K. Siegert / IFU
– Institute for Metal Forming, Technical University Stuttgart, Germany. ..55
1.4.2.5 Doege, E., Schaprian, M., Derenthal, M., Menz, R., Zacharov,
A., Elend, L., Hubner, S., Barnert, L., Huskic, A., Abdelfattah, S., (2002)
“Practice Oriented Developments at IFUM – The elastic blank holder” (in
German) Proceedings of 17th UKH, Hannover, pp. 63-100......................56
1.4.2.6 Gunnarsson, L., Schedin, E., (2001) “Improving the properties
of exterior body panels in automobiles using variable blank holder force”
Journal of Materials Processing Technology, Vol. 114, pp. 168-173........57
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