Indirect Strain Control in Aluminum Stamp Formed Pans

[+] Author and Article Information
William J. Emblom

University of Louisiana at Lafayette Department of Mechanical Engineering P.O. Box 44170 Lafayette, LA, USA

1Corresponding author.

ASME doi:10.1115/1.4036489 History: Received July 08, 2016; Revised April 01, 2017


A stamp forming die, whose flexible blank holder was designed using FEA was built. The tooling also included active draw beads, local wrinkling sensors, and local force transducers. Wrinkling was controlled using a PID feedback loop and blank holder force. Local forces in the tooling could be controlled using blank holder forces in a PID feedback loop. A third closed-loop control system that could be used to control local punch forces near draw beads featured an advanced PID controller with a Smith Predictor and Kalman Filter. A Bang-bang controller was also incorporated into that control system in order prevent control saturation. Fuzzy logic was used to transition from once controller to the other. Once closed-loop was implemented, tests were performed to evaluate the strains in the pans for various forming conditions. These results were compared to open-loop tests and it was found that the strains from closed-loop control tests resulted in more uniform strains and that the strains were further from the forming limit curves than strains from tests that were performed under open-loop conditions. Furthermore, it was seen that the strains in the regions were local force were controlled resulted in more uniform strain fields. Hence it was concluded that controlling local punch forces resulted in the strain control of critical regions.

Copyright (c) 2017 by ASME
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