LEAN PANEL BENDER – Einige mechanische Aspekte der Modellierung in Echtzeit für Produktion in Losgröße 1

Nachfolgend werden einige wissenschaftliche Aspekte der Echtzeit-Materialerkennungsstrategie MAC diskutiert, die in der neuen Maschinenfamilie LEAN PANEL BENDER der Firma Salvagnini Maschinenbau realisiert ist und die eine hochpräzise und hocheffiziente Herstellung von komplex geformten Blechprodukten sowohl bei Losgröße 1 als auch in der Serie erlaubt.(VLID)342339

Industrial application of advanced adaptive concepts for automatic panel benders

Recently, the requirements on sheet metal production processes have increased significantly. Highest precision and flexibility with efficient energy consumption and short cycle times can be achieved by advanced concepts only. This requires a deep insight into the non-linear bending process. For this sake, efficient simulation models have been implemented to model the bending process: two and three dimensional finite element models combined with multibody simulation tools, contact mechanics algorithms and substructure techniques. The simulation tools have been successfully calibrated by measurement results. With the obtained detailed process knowledge, new adaptive concepts have been introduced, e.g. a smart crowning system in order to achieve straight profiles. The industrial application has shown the advantage of utilizing the above mentioned techniques. The straightness of the bends has been significantly increased, while energy consumption and cycle times have been reduced. Secondly, the development time of new machine concepts has been drastically reduced, such that the first prototype can be transferred to series production within short time. Moreover, the applied strategies show a large potential for future developments

Advanced mechanical simulation models for automatic panel benders

With automatic panel benders complete products are manufactured from sheet metal. In order to achieve short cycle times with high flexibility, a deep insight into the non-linear bending process is required. For this reason, efficient mechanical simulation models have been implemented, combining Finite Element Method, multibody dynamics simulation tools, contact mechanics algorithms and substructuring. Scope of this work is the comparison of several simulation models with measurement results performed on a Salvagnini P4XeD automatic panel bender

Similarity methods in elasto-plastic beam bending

In industrial metal forming processes a large number of parameters has to be considered. As is well known, this number can be reduced by a non-dimensional representation. Based on the example of an elasto-plastic cantilever beam, the non- dimensional form is derived in the framework of the Bernoulli-Euler theory. In the second step, a Finite Element analyis of a drop-test experiment is performed, and the results are presented in non-dimensional form. The results illustrate the advantage of the normalization

Increasing numerical efficiency in coupled Eulerian-Lagrangian metal forming simulations

The coupled Eulerian-Lagrangian formulation is an efficient tool for modelling and simulation of metal forming processes with large deformation. In many cases, thermo-mechanical coupling has to be considered. Usually the numerical effort is very high for such processes, and large simulation times are the consequence. In this paper, strategies for reducing the simulation time are investigated, based on the example of a hot forming process

Similarity methods in elasto-plastic beam bending

In industrial metal forming processes a large number of parameters has to be considered. As is well known, this number can be reduced by a non-dimensional representation. Based on the example of an elasto-plastic cantilever beam, the non- dimensional form is derived in the framework of the Bernoulli-Euler theory. In the second step, a Finite Element analyis of a drop-test experiment is performed, and the results are presented in non-dimensional form. The results illustrate the advantage of the normalization

Comparison of coupled euler-lagrange and smoothed particle hydrodynamics in fluid-structure interaction

In this paper a fluid-structure interaction problem is investigated, in which fluid flow and flexible deformations of structures are coupled. Exemplarily, the collision of a moving deformable water-filled container with a rigid wall is considered. Two simulation methods are compared to analyze the impact: the Coupled Euler-Lagrange Finite Element Method (CEL) and Smoothed Particle Hydrodynamics Analysis (SPH). On the other hand, the solutions of two software packages are compared, the commercial Finite Element code Abaqus (CEL, SPH) and the open source package HOTINT/LIGGGHTS (SPH). Goal is to find the various advantages and disadvantages of the two simulation methods and the two software codes

Comparison of coupled euler-lagrange and smoothed particle hydrodynamics in fluid-structure interaction

In this paper a fluid-structure interaction problem is investigated, in which fluid flow and flexible deformations of structures are coupled. Exemplarily, the collision of a moving deformable water-filled container with a rigid wall is considered. Two simulation methods are compared to analyze the impact: the Coupled Euler-Lagrange Finite Element Method (CEL) and Smoothed Particle Hydrodynamics Analysis (SPH). On the other hand, the solutions of two software packages are compared, the commercial Finite Element code Abaqus (CEL, SPH) and the open source package HOTINT/LIGGGHTS (SPH). Goal is to find the various advantages and disadvantages of the two simulation methods and the two software codes

Advanced mechanical simulation models for automatic panel benders

With automatic panel benders complete products are manufactured from sheet metal. In order to achieve short cycle times with high flexibility, a deep insight into the non-linear bending process is required. For this reason, efficient mechanical simulation models have been implemented, combining Finite Element Method, multibody dynamics simulation tools, contact mechanics algorithms and substructuring. Scope of this work is the comparison of several simulation models with measurement results performed on a Salvagnini P4XeD automatic panel bender

Industrial application of advanced adaptive concepts for automatic panel benders

Recently, the requirements on sheet metal production processes have increased significantly. Highest precision and flexibility with efficient energy consumption and short cycle times can be achieved by advanced concepts only. This requires a deep insight into the non-linear bending process. For this sake, efficient simulation models have been implemented to model the bending process: two and three dimensional finite element models combined with multibody simulation tools, contact mechanics algorithms and substructure techniques. The simulation tools have been successfully calibrated by measurement results. With the obtained detailed process knowledge, new adaptive concepts have been introduced, e.g. a smart crowning system in order to achieve straight profiles. The industrial application has shown the advantage of utilizing the above mentioned techniques. The straightness of the bends has been significantly increased, while energy consumption and cycle times have been reduced. Secondly, the development time of new machine concepts has been drastically reduced, such that the first prototype can be transferred to series production within short time. Moreover, the applied strategies show a large potential for future developments