DK_Analysetechnologien für mehrstufige Umformprozesse auf Basis von Sensorischen Verbindungselementen und Dataminingtools

Analysis technologies for multi-stage forming processes using sensorial (HA-Project-No.: 422/14-22)



The product portfolio for multi-stage processes is characterized by high component complexity, integrated component functionality and strict quality requirements. The automatically linked processes are characterized by high investment costs and productivity. In production, the mechanisms of error emergence and propagation in interlinked stages are often unknown. Up to now, there was no measurement technique that allows capturing physically clear readings with a reasonable effort. The company ConSenses GmbH developed a bolt with integrated sensor element which is capable of capturing the bolt additional force. These PiezoBolts can be installed in accordance with a conventional bolt and can be used as a force sensor additionally.


Methods and technologies researched and developed in this project, will help to transfer the complex interactions of process, tools and semi-finished products to objective data. These data can be used as a basis for decisions. The aim is to develop new strategies for localization and avoidance of process errors by using the process data, recorded with PiezoBolts, and the knowledge of the fundamental research of failure development and propagation. Thus, a tool for process analysis and decision-making shell be created.

Methodical approach

Within this project, a multistage tool of the company Werner Schmid GmbH will be equipped with the PiezoBolts of ConSenses GmbH and monitored in series production. First, the detection of a reference curve during an ideal process, free from errors, must be carried out. This reference curve has to be stored in the analysis software of ConSenses GmbH and will be compared with the values recorded during the series production. In case of a process fault, the process force curve deviates from the reference force curve and therefore, all process failures will be detected clearly. The PtU will create numerical models of the first three deep drawing stages and the upstream cutting stage of the monitored tool. By linking the steps to one another in the FE, it will be possible to consider the error propagation within the stages. Among others, the simulation results will be used for a deeper process analysis. For example, the evaluation of local peaks of the contact normal stresses in the tool, resulting from component failures, will be enabled.


The research project is funded via the Hessen Agentur GmbH by the State of Hessen.