Industry 4.0 Formability Next Generation Optical Metrology for Sheet Metal Stamping Quality Control John “Yanni” Psilopoulos Technical Account Manger
Trilion ARGUS Technology Supporting automotive stamping operations for 20 years. Trilion Quality Systems
Trilion Quality Systems Trilion team Engineering Services User Meetings Customer Training
Agenda – Industry 4.0 Formability DIC for Material Properties Bulge & Nakajima Testing - FLC • Incoming Inspection - Tensile Testing – N-value • corrected FLC - for N- & Non-linear • Optical Forming Analysis (OFA) Patterning Chemical Etching vs Laser Etching • Laser Etching • Robotic Laser Etching • Optical Forming Analysis (OFA) Measurement OFA Formability • FEA Comparison • Automated OFA • DIC for Press Deflection Setup • Reporting • High & Low Speed testing •
Formability 4.0 Metrology Trilion is on the cutting-edge developing next generation technologies for industry. Today, Industry 4.0 Formability, providing precision measurement and automation, to assist with the lightweighting issues of stamping. Laser Incoming ARGUS ARGUS ScanBox ARAMIS HHS Etching Material FLC Optical Automated ARGUS Press Deflection Tests Forming Analysis Precision ARGUS ARAMIS Patterning TRILION ENGINEERING SERVICES Non-contact measurements
Tensile Test Incoming Inspection for Corrected FLC N-Value • Non-linear Forming •
DIC for Materials Testing
Measurement of Tensile Tests with DIC Full-field 3D data with DIC Determination of material parameters Any material Strain distribution Analyze local effects
Calculation of Material Parameters in DIC DIC Measurement Project Evaluation Image acquisition DIC measurement project definition and image processing 3D measurement data post-processing Calculation of tensile test relevant material parameters ∙Young’s modulus ∙Poisson ratio ∙Rp 0.2% ∙Rm, Ag ∙R-Value ∙N-Value ARAMIS for Materials Testing | GOM GmbH
Forming Limit Curve Analysis of sheet metal formability Material parameter curve describing the limit of forming of sheet metal materials The FLC describes the formability in the range from uni-axial to bi-axial deformation ARAMIS for Materials Testing | GOM GmbH
Forming Limit Curve Analysis of sheet metal formability Material parameter curve describing the limit of 1 forming of sheet metal materials The FLC describes the formability in the range from uni-axial to bi-axial deformation 1: Uni-axial strain condition ARAMIS for Materials Testing | GOM GmbH
Forming Limit Curve Analysis of sheet metal formability Material parameter curve describing the limit of 1 forming of sheet metal materials The FLC describes the formability in the range from uni-axial to bi-axial deformation 1: Uni-axial strain condition 2 2: Plain strain condition ARAMIS for Materials Testing | GOM GmbH
Forming Limit Curve Analysis of sheet metal formability Material parameter curve describing the limit of 1 forming of sheet metal materials The FLC describes the formability in the range from 3 uni-axial to bi-axial deformation 1: Uni-axial strain condition 2 2: Plain strain condition 3: Bi-axial strain condition ARAMIS for Materials Testing | GOM GmbH
DIC Kiosk Mode runs the Incoming Material Test automatically ARAMIS for Materials Testing | GOM GmbH
DIC for Precision Material Properties DIC Automated Incoming Inspection Performing material testing for complete knowledge of material • being used during the runs Automated with parametric templates for easy repeated • testing for high throughput Corrected FLC for N-value & Non-linear forming • Leading to correct forming limits for current coil sample • Leading to a more accurate tracking metric per production run • Reducing tool changes due to wrong material information • Understanding incoming material sample • Reducing tool changes due to material variation • Reducing press downtime • Leading to better panel quality • Leading to higher production output with less dedicated • resources
DIC and Industry 4.0 DIC allows the operator to automatically test material and report • to the entire team quickly and efficiently. The parametric functions allow for the operator to run sample • after sample without recreating the reports each time. The reporting template is saved and reused having all of the necessary data previously created. The automated kiosk mode is used in correlation in running • consecutive samples. Then the reports are automatically generated and exported to the entire team. The ability of gathering actual material data of incoming coils allow for the build facilities and production facilities to be proactive instead of reactive during tool runs. Thus leading to less overall downtime.
Sheet Metal Etching for Optical Formability Analysis
Measuring Principle – Optical Forming Analysis Patterning Apply regular dot pattern before forming ∙ Electro-chemical etching ∙Hazardous chemicals ∙Variable Accuracy ∙ Laser marking ∙Precise, on any material ∙Automated ARGUS – Optical Forming Analysis
Measuring Principle Computation of 3D coordinates of all dots with at least three camera positions Results for all measuring points ∙3D coordinates ∙Major and minor strain ∙Material thickness reduction Forming limit diagram Validation and optimization of numerical forming simulations ARGUS – Optical Forming Analysis
OFA Laser Etching: Autonomous Panel Marking for Precision Measurements Aim of the Solution: The autonomous laser etching robot provides perfectly marked panels, automatically, for optical formability measurements. This method substantially reduces labor requirements and training, while providing enhanced safety, for personnel and the environment. Expected Results: The results of this autonomous laser etching method will produce an accurately placed perfect dot/line pattern, for the entire panel, or for specific areas of concern. This pattern will have the proper contrast and is material independent, without the use of toxic chemicals.
OFA Laser Etching: Difficult Automotive Part Epsilon X Epsilon Y Epsilon X directional strain accuracy is at +/-0.2% Epsilon Y directional strain accuracy is at +/-0.2% (Epsilon X is strain from left to right) (Epsilon Y is strain from top to bottom) - The Laser Etching Process took 6.5min/grid - Each Grid is 12in square - Etching Error 2-5x better than manually
OFA Laser Etching: Difficult Automotive Part Major Strain Minor Strain Thickness Reduction Perfect Laser Etch, with substantially better results than manual chemical etching.
Autonomous Laser Etching Robot – Industry 4.0 Formability OFA Laser Etching Robot Cost Saving by allowing the laser to perform the precision etching, • perfectly every time, for any material. Saving $250k/year • No more wasted manhours etching questionable quality grids • Cost saving on material • Cutting material waste from badly etched panels • Better knowledge of binder pull-in for better material utilization. • Increased accuracy of critical lightweighting panels • More accurately etched panels allowing for more accurate • formability results More accurate designs on non-linear strain paths. • Fixing non-linear forming errors • Reducing downstream splits • Reducing vehicle structural recalls • Reducing warranty issues • Happy Customers … Happy Corporation • The cost savings are measurable on a per unit, man hour, and hourly • Machine/Assembly Line downtime. “Green” environmentally friendly • No Hazardous Chemicals needed • Etching area can be easily placed or moved to anywhere in the plant •
Autonomous Laser Etching Robot and Industry 4.0 Autonomous Laser Etching unit allows the ability to create • repeatable and accurate pattens for OFA (Optical Forming Analysis). OFA patterns that have the least amount of noise will give the use • the most accurate results needed to make more informed decisions. Autonomous Laser Etching now allows the a “set it and forget it” • setup. The user places the unit down and allows it to perform the operation Repeatable accurate pattern is created each time. This leads to less material waste, less tool downtime and better • overall data of the formability process. A library of patterns with settings is created and called upon each time a panel needs to be checked.
Optical Forming Analysis
Optical Forming Analysis - Process ARGUS – Optical Forming Analysis
Optical Forming Analysis - Result ARGUS – Optical Forming Analysis
Optical Forming Analysis Applications Monitoring of Process Stability in series production
Verification of Numerical Simulations Import of FEA data 3D coordinate system alignment ∙ Best-fit ∙ Manual registration ARGUS – Optical Forming Analysis
Verification of Numerical Simulations Import of FEA data 3D coordinate system alignment ∙ Best-fit ∙ Manual registration Calculation of surface (geometry) deviations ARGUS – Optical Forming Analysis
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