Research Papers

Pressure and Draw-In Maps for Stamping Process Monitoring

[+] Author and Article Information
Sripati Sah

Persimmon Technologies Corp.,
Wakefield, MA 01880

Numpon Mahayotsanun

Department of Mechanical Engineering,
Faculty of Engineering,
Khon Kaen University,
Khon Kaen 40002, Thailand

Michael Peshkin, Jian Cao

Department of Mechanical Engineering,
Northwestern University,
Evanston, IL 60208

Robert X. Gao

Department of Mechanical
and Aerospace Engineering,
Case Western Reserve University,
Cleveland, OH 44106

1S. Sah and N. Mahayotsanun contributed equally to this work.

Manuscript received November 15, 2015; final manuscript received March 8, 2016; published online June 20, 2016. Assoc. Editor: Matteo Strano.

J. Manuf. Sci. Eng 138(9), 091005 (Jun 20, 2016) (15 pages) Paper No: MANU-15-1585; doi: 10.1115/1.4033039 History: Received November 15, 2015; Revised March 08, 2016

This paper presents two tooling-integrated sensing techniques for the in situ measurement and analyses of pressure distribution at the tool–workpiece interface and material draw-in during the stamping processes. Specifically, the contact pressure distribution is calculated from the measurements by an array of force sensors embedded in the punch, whereas sheet draw-in is measured by custom-designed thin film sensors integrated in the binder. Quantification of the pressure distribution from spatially distributed sensors has been investigated as a regularization problem and solved through energy minimization. Additionally, a Bayesian framework has been established for combining finite-element analysis (FEA) based estimates of the pressure distribution with experimentally measured evidence, to achieve improved spatiotemporal resolution. A new data visualization technique termed pressure and draw-in (PDI) map has been introduced, which combine spatiotemporal information from the two sensing techniques into an illustrative representation by capturing both the tool–workpiece interaction (dynamic information) and resulting workpiece motion (kinematic information) in a series of time-stamped snap shots. Together, the two separate yet complementary process-embedded sensing methods present an effective tool for quantifying process variations in sheet metal stamping and enable new insight into the underlying physics of the process.

Copyright © 2016 by ASME
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Fig. 1

Illustration of the physical setup of stamping operation

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Fig. 2

Current state of sensing and the proposed technique

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Fig. 3

Top-mount sensing schematic and prototypes

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Fig. 4

Effect of embedding clearance on local pressure distribution

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Fig. 5

Effect of clearance on top-mount sensor performance

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Fig. 6

Draw-in sensor based on the mutual inductance

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Fig. 7

Schematic of draw-in sensor for induced EMF calculation

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Fig. 8

Schematic of electromagnetic simulation considering the electromagnetic properties of the metal

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Fig. 9

Electromagnetic simulation results of induced voltage (EMF) versus displacement of AA3003 sheet having 0.76 mm thickness

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Fig. 10

Draw-in sensor transducers design and development

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Fig. 11

Lab-scale draw-in testing apparatus

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Fig. 12

Induced voltage versus displacement of AA3003 sheet having 0.76 mm thickness

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Fig. 13

Slope (induced voltage/displacement) versus sheet thickness comparison

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Fig. 14

Large-scale experimental setup with tooling-integrated force and draw-in sensors

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Fig. 15

Pressure measured at 12 locations in three repeated tests [10]

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Fig. 16

TD locations in the die and binder

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Fig. 17

Draw-in amount versus punch position of the stamping test of AA5182 having 1.56 mm thickness

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Fig. 18

Contact pressure at punch–workpiece interface estimated by FEA, Bayesian, and TPS

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Fig. 19

PDI map of the stamping process indicating pressure distribution (MPa) and draw-in (3 × mm)

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Fig. 20

PDI map of the stamping process indicating pressure distribution (MPa) and draw-in (3 × mm)




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