In-Process Measurement of Elastic Deformation of a Large Deep-Drawing-Die

with Fusion of Experiment and Numerical Analysis

Paper:

In-Process Measurement of Elastic Deformation

of a Large Deep-Drawing-Die
with Fusion of Experiment and Numerical Analysis
Takahiro Ohashi∗ , Tomoaki Ando∗∗ , and Noriyuki Nakaoka∗∗
∗ Kokushikan University
3-4-1 Setagaya, Setagaya-ku, Tokyo 154-8515, Japan
E-mail: tohashi@kokushikan.ac.jp
∗∗ Advanced Simulation Technology of Mechanics (ASTOM) R&D, Co. Ltd.

2-3-13 Minami, Wako-shi, Saitama 351-0104, Japan

[Received September 9, 2008; accepted March 24, 2009]

We measured elastic deformation of a large deep
drawing die in-process and visualized it with a fusion
technique of numerical analysis and experiments with
multipoint die support. We found that displacement
by elastically deforming a press machine bolster is up
to 0.15 mm when measured directly by displacement
sensors. Lower die profile displacement for a half size
fender is estimated at 0.25 mm. We numerically ana-
lyzed elastic die deformation using multipoint die sup-
port to measure and visualize deformation indirectly.
We calculated reactive force distribution on the cavity
surface and to know it differs with according to distri-
bution pattern of support points, and visualized elastic
deformation die patterns.
Keywords: die, press-working, deep drawing, in-process
measurement, numerical analysis
1. Introduction
Phenomena in die-cavity must be known to determine
their relationship to product defects. General numerical
analysis had been developed to help determine this rela-
tionship is useful, but has limitations of ability dealing
with the problem. An analysis model could not meet for
the actual condition because of its uncertainty. For ex-
ample, it is not easy for commercial analysis to deal the
problem of machine difference and uncertainty of the die-
setup. In-process measurement enables us to know the
above phenomena as it is, and we can say that it is a key
to solve the actual problems which is difficult to be solved
with using only commercial simulations.
Ohanaka et Al. uses x-ray photography to determine
the material flow in a casting mold [1]. Yokoi and Murata
used pin-arrays on a touch-sensing sheet to measure injec-
tion mold cavity surface pressure distribution [2]. Murata
also used strain gauges to measure elastic mold deforma-
tion to detect fin outbreak [3]. In the rolling process, em-
bedded sensors have been used to measure roller surface
pressure distribution [4 – 5]. Such the embedded sensor is
also found in the study of drawing [6].
In the deep drawing for large products such as auto-
mobile panels, the die deforms elastically, but exactly
how is unknown. Yoshida et al. analyzed spring-back in
sheet metal forming considering elastic die deformation
and found differences in analytical results under rigid- and
elastic-die assumptions [7].
2. Problems of Machine Difference in Large
Deep Drawing
Figure 1 despites typical flow chart for the starting-up
of production of a large deep drawing part for an automo-
bile. Though a product is made in multiple distributed
shops in the world to avoid risk, its dies are designed,
manufactured and examined in a certain mother shop gen-
erally. They do not work as it is designed often because
of their elastic deformation, spring-back of a material and
other causes unconsidered in design. Therefore many tries
and corrections are needed in a trial line of the mother
shop. After the try-out the dies are shipped to production
lines of satellite shops. However the shipped dies do not
work often in a satellite shop too. It is considered it comes
from machine difference. Many causes are expected such
as difference of rigidity of machine and floor, motion of
slide, reaction of cushion and so on, but have not been
revealed sufficiently. They only make many tries again
in the satellite shop and re-correct the dies. It takes long
time and costs additionally. If the starting-up in a satellite
shop delays, the other shops must wait until it get ready
in international concurrent manufacturing.
In-process monitoring of die behavior is considered ef-
ficient for determining the cause of and solving problems.
We compare the results of in-process monitoring between
parent-shop trial lines and satellite shop production lines.
We measured elastic deformation of a large deep draw-
ing die in process and visualized with employing fusion
of numerical analysis and experiment with the dedicated
multipoint die support.

Int. J. of Automation Technology Vol.3 No.4, 2009 457

Ohashi, T., Ando, T., and Nakaoka, N.

Fig. 1. Steps in mass production starting-up of large deep drawing parts.

Table 1. Experimental conditions.

Specimen SPCC 0.8 mm thick

Lubricant Nihon Kohsakuyu EPH-7570
Forming machine Amino FP500C
(maximum load: 5000KN)

Fig. 3. Lower model die.

Fig. 2. Upper model die.

3. Overview of Experiments and Conditions

Following two experiments, direct die-deformation
measurement and indirect die-deformation measurement
combining experiments and numerical analysis are per-
formed. Table 1 shows their common experimental
conditions. The half-scale-model automobile-fender die
(Figs. 2 and 3) we used in two experiments and analysis
is made of FC50 cast iron and having a flat die-backplane.
Fig. 4. Measurement of elastic press-machine and die bol-
ster deformation.
3.1. Direct Die-Deformation Measurement
We measured press-machine and lower-die bolster de-
formation directly using displacement sensors (Fig. 4). measured relative bolster profile displacement between
We inset distributed load cells between the die and bol- pins and calculated load-cell height displacement from
ster to make room for displacement sensors attached to a measured loads to roughly determine die deformation by
straight floating bar with adjustment pins at both ends. We adding both displacements.

458 Int. J. of Automation Technology Vol.3 No.4, 2009