Plenary Lecture

Plenary Lecture

Metal Forming Process Control based on
Reduced Order Model

Professor Catalina Maier
Manufacturing Science and Engineering Department
University of Galati

Abstract: Sheet metal stamping is an important manufacturing process because of its high speed and low cost for mass production. The control of flow of material into the die cavity is crucial to good part quality and consistency. Different solutions are developed in this field: i). MPF multi-point forming is a flexible manufacturing technique for the forming of 3D surfaces of the sheet metals; MFR is dividing the curved surface of the die into many discrete pins, using many punches instead of the traditional die, and each punch can be controlled by computer; ii). DDF digitized-die forming is a method to form the part section by section and this technique makes is possible to manufacture large-size parts in a small DDF press; iii). VP-DDF Varying path DDF consist in a continuous variation of the shape of the digitized-die during the forming process, using a geometrical criteria; iv). Multi-step DDF is approximate to VP-DDF; in this technique the forming process is completed through many forming steps and the final deformation of the parts is accumulated by a series of small deformations in each step; because of the small deformation of the sheet, the forming defects such as wrinkling, tearing and dimpling can be avoided completely; v). Closed-loop forming system was build by combining DDF with rapid 3D-shape measurement system. All this techniques assure the control of the forming process by geometrical criteria and those can be applied for particular shape of the parts. The main objective of this paper is to present a new method for metal forming process control based on reduced order modelling. The reduced order model is obtained considering the material response during the metal forming process and assure the real-time control. Identification of the reduced order model parameters is made considering a data base obtained by finite element simulation and experimental tests.

Brief Biography of the Speaker:
Dr. Maier graduated Faculty of Mechanical Engineering of University Dunarea de Jos of Galati in 1979, and she obtained the title of Doctor Engineer in 1997. In the next year, Dr. Maier was awarded with a post-doc grant of The Mechanical and Thermodynamical Materials Properties Laboratory LPMTM, University Paris 13, France.
Since 1983 she followed the academic carrier at Dunarea de Jos University of Galati as researcher associate professor and professor. Dr. Maier was a visitor scientist of The University Paris13, France and, in the period 2000-2003 she was visiting professor in The Mechanical and Thermodynamical Materials Properties Laboratory of the Galilee Institute, University Paris 13, France. Research fields are connected with characterisation, modelling and control of the nonlinear behaviour of materials undergo to large plastic deformations, multiscale modelling of the materials under large plastic deformation within manufacturing the parts by metal forming, integrated system researches of the body cars. In the mentioned subject, Dr. Maier published 53 articles in journals and internationals conferences proceedings, she is author and co-author of 8 books and she delivered 7 invited conferences in France. The research was done as director or member of 38 research contracts financed by European Commission and Romanian Ministry of Education and Research. The strong cooperation with The Mechanical and Thermodynamical Materials Properties Laboratory LPMTM, University Paris 13, France contributed to the enhancement of the research studies on modelling the material behaviour within metal forming. Dr. Maier is a member of international scientific societies as follows: European Scientific Association of Materials Forming - ESAFORM, since 1997, Society of Automotive Engineers of Japan, since 2006.




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