Cyber Physical Production Systems for Deep Drawing

Deep Drawing is an essential manufacturing technology for car body parts. High process stability is a key for reducing scrap and therefore the ecological footprint during the production. To deal with an unknown fluctuation of the incoming material properties and uncertainties considering the friction, an adaptive process needs to be implemented. Various approaches have been pursued in the past, but not all of them are suited for an industrial series production with high demands for equipment durability, cost efficiency and flexibility. For this reason, a new concept for cyber physical production systems (CPPS) in deep drawing is presented, linking the data from the simulation, tool, press, material and finished part quality. Two common application scenarios are distinguished. These are firstly large outer parts with a complex geometry and high value, typically produced with tandem presses. Secondly smaller structural parts from high strength steel for the body in white (BIW), usually produced through a transfer or progressive die. Non destructive material testing, supplier material certificates and data measured directly in the forming tool are considered regarding the input. A variation of the servo curve and blank holder force (BHF) operate as control instances. Within the two application scenarios, a reactive and a preventive solution are characterized. As a first step towards the implementation of the CPPS, material inflow and force sensors are installed in an industrially relevant deep drawing tool.