MIMO Adaptve Process Control in Stampin.doc

MIMO Adaptive Process Control in Stamping Using Punch Force By Yongseob Lim In stamping, both manufacturing and control engineers have faced challenges to prevent stamped parts from wrinkling and tearing, to improve their dimensional accuracy (e.g., to minimize springback), and to maintain consistency in the stamping process (e.g., reduce variations in stamped part quality). In this research, a process control strategy is introduced in sheet metal stamping to improve the quality of stamped parts and the consistency of the stamping process. Sheet metal stamping is a primary manufacturing process for large-volume highspeed and low-cost production of components, such as panels in automobiles and home- appliances. A stamped part is made by placing a sheet of metal (the blank) between an upper die (or punch) and a lower die，which are geometric negatives of each other, and then stamping the sheet of metal using a press. A blank holder, or binder, is used to hold the edges of the sheet of metal，and to control the flow of material into the die, sometimes using drawbeads, which provide additional restraining forces on the blank. Once die design and validation are accomplished, high productivity is the hallmark of stamping operations due to their suitability for large-volume production. As shown in Figure 1.1,1， a punch (i.e., upper die) is forced towards the lower die, with the material to be drawnplaced in between. In Figure 1.1.1, Fp is the punch force，ls is the material draw-in, h is the punch stroke, and Fb is the binder (or blank holder) force. Traditionally, stamping presses have been mechanical in design, but modern presses are often electro-hydraulic. Presses also typically have rubber, springs, and pneumatic/hydraulic pistons to passively cushion the die in a stamping press from the punch impact. Figure 1.1.1: Schematic of the sheet metal stamping process including process varia