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R&D Update: Industry 4.0 and the use of sensors in

sheet metal forming
STAMPING JOURNAL NOVEMBER/DECEMBER 2018 (/PUBLICATION/SJ/SJ-NOVEMBER-DECEMBER-2018)
DECEMBER 6, 2018
BY: DAVID DIAZ INFANTE (/AUTHOR/DAVID-DIAZ-INFANTE), TAYLAN ALTAN, PH.D. (/AUTHOR/TAYLAN-ALTAN)

Industry 4.0 is an initiative that aims to drive digital

manufacturing forward by increasing digitization and
interconnection of products, value chains, and
business models. In simpler words, this initiative
suggests to improve a given process by recording
and using all the information available from the very
beginning of the process to its end.

Data mining (see Figure 1) now is possible thanks to

the various systems that can measure and control
different aspects of a given process. Data mining can
be applied to sheet metal forming, with the main
objective being to form a defect-free part of desired
(https://static.thefabricator.com/a/r-d-update-industry-4-0-and-
dimensions, without wrinkles or fractures. This
the-use-of-sensors-in-sheet-metal-forming-1544121749.jpg?
objective can be achieved by measuring and/or
size=1000x1000)
controlling material properties, material flow,
lubrication conditions, forming forces, surface
roughness, and tool dynamics. Figure 2 shows examples of sensors used to measure some of these parameters.

Material Flow Measurement

Measuring the amount of material flowing into the die cavity is useful to control the forming process. On one hand,
insufficient material flow may lead to excessive thinning and eventually to fracture. On the other hand, excessive
material flow can cause wrinkles.

AUDI AG plants in Neckarsulm and Ingolstadt use laser sensors to measure the material flow. This information is sent
to an algorithm that electronically adjusts, per stroke, the height of the spacers, which are two wedges located
between the lower die and the blank holder/binder to control material flow into the die cavity.

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18.12.2018 R&D Update: Industry 4.0 and the use of sensors in sheet metal forming - The Fabricator

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Measurement of Forces
Force sensors, also referred to as tonnage monitors, can record either the peak load values or the load as a function
of slide displacement or time. These sensors typically are placed in the press frame, the connecting rods, the slide, or
directly in the tool.

Force measurement can be used to prevent press overloading or off-center loading, to monitor tool wear, and to detect
changes in lubrication or material fracture (see Figure 3a). Load cells and piezoelectric sensors are the most
commonly used force-measuring devices.

Detection of Tool Breakage and Part Flaws

In addition to force sensors, ultrasonic or acoustic emission sensors also can be employed to detect some changes in
the process (see Figure 3b). When a crack is generated in the workpiece or tool, waves are propagated from this
crack and can be recorded by ultrasonic and acoustic emission sensors. Special care is required to locate and
interpret results from this type of sensor, since noise signals can interfere with the measurements.

Displacement Sensors
Typically used for tracking the die position to prevent crashes, displacement sensors also can be used to detect
wrinkle initiation on the flange of the blank during a stamping or deep drawing process. Displacement sensors can
indicate when wrinkling occurs in the flange (see Figure 3c).

This technique can be important in an automated process in which the blank holder force can be adjusted locally.
Linear variable differential transformers, proximity sensors, ultrasonic sensors, and photoelectric sensors are used for
these tasks.

Online Material Property Evaluation

The material’s mechanical properties have a significant effect on processing conditions and part quality. The material’s
formability can be determined by the yield strength, ultimate tensile strength, uniform elongation, elongation and
fracture, and hardness, and all these properties can vary from batch to batch or even within the same batch.

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18.12.2018 R&D Update: Industry 4.0 and the use of sensors in sheet metal forming - The Fabricator

(https://static.thefabricator.com/a/r-d-update-industry-4-0-and-the-use-of-sensors-in-sheet-metal-forming-
1544125733.jpg?size=1000x1000)
Figure 1
These are the basic principles of using the data mining method in the press shop (Meinhardt et al, 2018).

Therefore, in large-volume production, it is good practice to measure each coil’s properties before use. This can be
accomplished by conducting tensile tests or using an eddy current sensor. When the material’s mechanical properties
are identified, adjustments can be made to press speed, blank holder force, and lubrication to improve forming results.

Lubrication Control
The amount and type of lubricant required can vary depending on its main purpose: cooling the blank and tools,
reducing tool wear, or improving material flow. The amount can also depend on the surface roughness of the material
under consideration.

Techniques such as spectroscopy can be used to measure lubricant thickness in real time during production. BMW
has installed a system that records the amount of lubricant along the width of the incoming coil. An additional system,
placed along the sensor measuring lubricant thickness, adds a tailored amount of lubricant to a target spot where a
lack of lubricant is detected.

Application of Industry 4.0 at the BMW Group

BMW has applied data mining successfully at its press shop in Regensburg, Germany, improving production of the 3
Series Sedan side frame made of 0.7-millimeter-thick DC03.

All the information required is tracked from the beginning to the end of the process. Sensors continuously record
lubricant film thickness, mechanical properties, sheet thickness, and sheet topography. The side frames are marked
with 10-digit alphanumeric code. Cameras using optical character recognition read the code. In series production, up
to 18 sample records per minute can be generated per press line.

Data mining showed some trends, such as larger concentrations of lubricant either at the beginning or at the end of the
strip. Also, variations in thickness were most common toward the end of the coil, even when the material thickness
was within specifications (0.7 +/- 0.035 mm). Using all the collected data and decision trees, BMW can track flaws on
parts back to the root of the problem to improve its manufacturing process.

References

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18.12.2018 R&D Update: Industry 4.0 and the use of sensors in sheet metal forming - The Fabricator

J. M. Allwood et al, “Closed-loop control of product properties in metal forming,” CIRP Annals, Vol. 65, No. 2 (2016),
pp. 573-596.

J. Meinhardt, R. Hummelsberger, K. Grossenbacher, and S. Purr, “Strategic orientation of the BMW Group’s Press
Shops,” in proceedings from New Developments in Sheet Metal Forming, IFU-Technical University of Stuttgart, May
15-16, 2018, pp. 187-194.

 Slide Show | 4 Images

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1544125740.jpg?size=1000x1000)
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David Diaz Infante

Center for Precision Forming at The Ohio State University

1971 Neil Ave.
Columbus, OH 43210

Contact via email (mailto:diazinfantehernandez.1@osu.edu)

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The Ohio State University
1971 Neil Ave.
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