ROTAFLEXEXPERT – Development of a method for process design and monitoring in rotary swaging
The ROTAFLEXEXPERT project is investigating the real-time acquisition of process parameters during rotary swaging close to the forming zone. The novel measurement system enables the process to be optimised in terms of economic, technical, and resource-saving objectives. The results offer a technological leap towards the individual forming of rotationally symmetrical components.
Motivation
Rotary swaging is a cold forming process for forming rotationally symmetrical components. The diameter of bars or tubes is reduced by rotating tools that act radially on the component at high speed, causing incremental deformation. Rotary swaging requires a high level of development and tooling and is therefore currently only economical to produce components in large series with very high volumes and long product lifecycles, for example in the automotive industry.
Tooling and process parameters usually have to be developed, tested and adjusted through a time-consuming and costly trial-and-error approach. Due to the lack of clarity in process parameters, the process is often evaluated based on the machine behaviour subjectively recorded by the operator and the resulting process noise, and then adjusted and optimised using the various process parameters in trial-and-error based on domain specific knowledge.
The heavy reliance on personal experience for the best possible setting and operation of the process and machine requires a high degree of specialisation. This results in high costs and the process can only be used economically for large series. At this point, the ROTAFLEXEXPERT project aims to create a comprehensive understanding of the process through sensor technology and process evaluation, so that these processes can be designed in a data-driven manner in the future. This leads to new applications for the process in industry.
Approach
The solution is based on the measurement of the rotational feed angle. This is regarded as a resultant variable and cannot yet be specifically set, nor are there any suitable industrial approaches to measuring it. The slip and torsion of the component can be recorded by measuring points before and after the formingzone, as well as the rotation specifications via the drive. The rotary feed angle can be determined by analysing these measuring points.
In a first step, a highly sensitive measuring system to record the rotary feed angle will be implemented using simulations and practical tests. This system will be used for the first time to realise a data-driven process startup for a new component. The findings from the highly sensitive solution can be used to adapt a robust solution that is suitable for use in production. The fine resolution relevant for research is reduced and replaced by a more resilient system. This should ensure that the relevant process variables can be recorded with sufficient accuracy even under production conditions in a permanently harsh environment.
Once the previous steps have been completed, a model for determining the optimum process conditions for rotary swaging can be created on the basis of the measured variables recorded by the sensors. This model will be adapted and tested for industrial use.
Acknowledgement
This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision of the German Bundestag.
We would also like to thank our project partner IPG – IFUTEC Produktions GmbH for their cooperation in the realisation of the project.
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