2004 Fiscal Year Final Research Report Summary
Intelligent Tube Hydroforming Process with Micro Contact Sensors
| Project/Area Number |
15360392
|
|---|
| Research Category |
Grant-in-Aid for Scientific Research (B)
|
| Allocation Type | Single-year Grants |
|---|
| Section | 一般 |
|---|
| Research Field |
Material processing/treatments
|
|---|
| Research Institution | Tokyo Metropolitan University |
|---|
Principal Investigator |
MANABE Ken-ichi Tokyo Metropolitan University, Graduate School of Eng., Professor, 工学研究科, 教授 (10145667)
|
|---|
| Co-Investigator(Kenkyū-buntansha) |
YANG Ming Tokyo Metropolitan University, Associate Profeasor, 工学研究科, 助教授 (90240142)
KOYAMA Hiroshi Yokohama National University, Graduate School of Eng., Research Associate, 大学院・工学研究院, 助手 (70345479)
|
|---|
| Project Period (FY) |
2003 – 2004
|
| Keywords | Tube Hvdroformin / Micro Contact Sensor / Intelligent Control / Fuzzy Inference / T-joint Forming / Finite Element Simulation / Forming Process Path / Ontimization |
|---|
| Research Abstract |
In this study, to establish an intelligent process control system for tube hydroforming, a new micro contact sensor is developed to evaluate the tool fitting state with a tubular blank and to make the forming system more accurate and more flexible based on their sensor fusion concept. The main research items are (1) to develop a micro contact sensor and evaluation its performance, and (2) to confirm the effectiveness of intelligent process control system utilizing the micro contact sensors. The study approaches are not only in experimental work but also in finite element (FE) simulation work to achieve the goal. The study results are as follows,
(1) Development of a micro contact sensors
A new sensor chip consists of nine sensors with a piezoelectric transducer, which is made by hand. Its output shows a linear relationship with applied load and enough performance as a contact sensor. The sensor chip were embedded on the head of a counterpunch for T -joint forming. As a result, it is foun
… More
d that the sensor can use as contact sensor well in the real process and the actual contact situation with tubular blank and counterpunch is different from FE simulation result. In other words, these results imply that actual intelligent forming system needs the contact sensor and has to control the process based on the sensing contact data. However, embedded sensors were not in good alignment on the counter punch head, it affects worse surface quality of T -shape accuracy. These technological issues on present developed sensors shall be solved including the principle of sensor in the near future.
(2) Intelligent control system and evaluation function of tool fitting, wrinkling, and rupture
Improvement of intelligent control algorithm including evaluation function of wrinkling, rupture, and tool fitting are made. Especially, a new algorithm to evaluate contact condition from sensing data is proposed and adopted in the fuzzy model. The new method, however, has some limitation of applicable scope in the case of wrinkling occurrence at the forming process. Although there have been remaining various problems on micro contact sensor and establishment of intelligent control algorithm and system utilizing the sensors, this two-year project results indicate that at least these micro contact sensors are essential to establish this system more advanced and more flexible. Less
|
Research Products
(8 results)
