TY - GEN

T1 - Concept of a control system based on 3D geometry measurement for open die forging of large-scale components

AU - Quentin, Lorenz

AU - Beermann, Rüdiger

AU - Brunotte, Kai

AU - Behrens, Bernd-Arno

AU - Kästner, Markus

AU - Reithmeier, Eduard

N1 - Funding Information: The results presented in this paper were obtained within the Collaborative Research Centre 1153 Process chain to produce hybrid high performance components by Tailored Forming in the subproject C5. The authors would like to thank the German Research Foundation (DFG) for the financial and organisational support of this project. The authors would also like to thank Mr. Michael Till for the fruitful discussion leading to the creation of this concept.

PY - 2020/4/1

Y1 - 2020/4/1

N2 - Hot forming processes, especially open die forging, are often used for production of high-performance, large-scale objects. The main benefits compared to, e.g. shape cutting methods, include lower material use and higher stress resistance. Inline process control by 3d geometry measurement is an important part of a cost-effective component production. However, there are no automated control systems commercially available for open die forging, which results in a limited precision of the final component geometry. The main challenges for a control system in said conditions are imposed by the temperature influence of the hot object on the measurement systems as well as limited actuator accuracy for the precise handling of hot, heavy objects. Additionally, the tools used in open die forging are kept simple for financial reasons. Comparable tools for, e.g., drop forging, need to be exclusively made for each new object form and therefore cannot be used for a cost-efficient production of low-quantity components. In this paper, we present a production concept in order to control a hot forming method for large scale, low quantity components. The approach combines an adaptable high-resolution 3d geometry measurement system and an incremental open die forging press for cost- and time-efficient production. Forming simulations will need to be conducted prior to the process to gain access to a large database of possible forming steps to reach the desired final geometry. The control system itself compares the measured geometry and temperature to the simulated ones. Occurring deviations are analysed and a sequence of forming steps is calculated from the database. The necessary forging forces and strokes of the actuating system are extracted from the chosen forming sequence and linked back into the system to achieve maximum precision.

AB - Hot forming processes, especially open die forging, are often used for production of high-performance, large-scale objects. The main benefits compared to, e.g. shape cutting methods, include lower material use and higher stress resistance. Inline process control by 3d geometry measurement is an important part of a cost-effective component production. However, there are no automated control systems commercially available for open die forging, which results in a limited precision of the final component geometry. The main challenges for a control system in said conditions are imposed by the temperature influence of the hot object on the measurement systems as well as limited actuator accuracy for the precise handling of hot, heavy objects. Additionally, the tools used in open die forging are kept simple for financial reasons. Comparable tools for, e.g., drop forging, need to be exclusively made for each new object form and therefore cannot be used for a cost-efficient production of low-quantity components. In this paper, we present a production concept in order to control a hot forming method for large scale, low quantity components. The approach combines an adaptable high-resolution 3d geometry measurement system and an incremental open die forging press for cost- and time-efficient production. Forming simulations will need to be conducted prior to the process to gain access to a large database of possible forming steps to reach the desired final geometry. The control system itself compares the measured geometry and temperature to the simulated ones. Occurring deviations are analysed and a sequence of forming steps is calculated from the database. The necessary forging forces and strokes of the actuating system are extracted from the chosen forming sequence and linked back into the system to achieve maximum precision.

KW - Fringe projection

KW - Hot forging

KW - Photogrammetry

UR - http://www.scopus.com/inward/record.url?scp=85120976517&partnerID=8YFLogxK

U2 - 10.1117/12.2554720

DO - 10.1117/12.2554720

M3 - Conference contribution

T3 - Proceedings of SPIE - The International Society for Optical Engineering

BT - Optics and Photonics for Advanced Dimensional Metrology

A2 - de Groot, Peter J.

A2 - Leach, Richard K.

A2 - Picart, Pascal

T2 - Optics and Photonics for Advanced Dimensional Metrology

Y2 - 6 April 2020 through 10 April 2020

ER -