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Procedia Manufacturing 15 (2018) 570–577
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia
17th International Conference on Metal Forming, Metal Forming 2018, 16-19 September 2018,
17th International Conference on MetalToyohashi,
Forming, Metal
Japan Forming 2018, 16-19 September 2018,
Toyohashi, Japan
A predictive model for die roll height in fine blanking using
A predictive
Manufacturing model
Engineering for International
Society die roll height in fine
Conference 2017, blanking
MESIC 2017,using
28-30 June
machine learning methods
machine learning methods
2017, Vigo (Pontevedra), Spain
Joachim Stanke*, Andreas Feuerhack, Daniel Trauth, Patrick Mattfeld, Fritz Klocke
Costing
Joachim models for capacity
Stanke*, Andreas Feuerhack, optimization
Daniel Trauth,inPatrick Industry Mattfeld,4.0:FritzTrade-off
Klocke
between used Engineering
capacity (WZL)and operational efficiency
Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Steinbachstr. 19, 52074 Aachen, Germany
Laboratory for Machine Tools and Production of RWTH Aachen University, Steinbachstr. 19, 52074 Aachen, Germany

A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
Abstract b
Unochapecó, 89809-000 Chapecó, SC, Brazil
A method for the development of a predictive model for the die roll height in fine blanking using artificial neural networks and
A method
support for the
vector development
machines of a predictive
is presented. model neural
Since artificial for the networks
die roll height in big
require fineamounts
blankingofusing artificial
training neural
data and networksusing
generation and
support vector
experiments is machines
very time is presented.and
consuming Sincecostartificial neural
intensive, networks
a validated FErequire
model big amounts
is used of training
instead. data and
The required generation
training using
data will be
experimentsusing
Abstract
determined is very time consuming
learning curves. The and cost intensive,
optimal a validated
architecture FE model is of
and hyperparameter used
theinstead. The
artificial required
neural training
network will data will be
be derived.
determined
Additionally,using learning
the die curves.is The
roll height optimal
modelled architecture
using and hyperparameter
support vector machines and of theconventional
also artificial neural network
statistical will be derived.
regression models.
Additionally,
Under
Finally the the dieofroll
theaccuracy
concept theheight
of is modelled
"Industry
methods is 4.0",
compared. using supportprocesses
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will beandpushed
also conventional statistical regression
to be increasingly models.
interconnected,
Finally the accuracy
information based of onthe methods
a real timeisbasis
compared.
and, necessarily, much more efficient. In this context, capacity optimization
© 2018
goes The Authors.
beyond Published
the traditional aimby of
Elsevier
capacityB.V.maximization, contributing also for organization’s profitability and value.
© 2018
© 2018 The Authors.
The Authors. Published
Published byby Elsevier B.V.
Peer-review
Indeed,
Peer-review under
lean
under responsibility
management
responsibility of Elsevier
and
of the B.V.
scientific
continuous
the scientific committee ofthe
improvement
committee of the17th
17th International
approaches Conference
suggest
International capacity
Conference onMetal
on Metal Forming. instead of
optimization
Forming.
Peer-review under responsibility of the scientific committee of the 17th International Conference on Metal Forming.
maximization. The study of capacity optimization and costing models is an important research topic that deserves
Keywords: Fine blanking; Die roll; Machine learning; Artificial neural networks; Predictive modelling, Support vector machines
contributions from both
Keywords: Fine blanking; Die the
roll; practical and theoretical
Machine learning; perspectives.
Artificial neural This paper
networks; Predictive presents
modelling, andvector
Support discusses
machinesa mathematical
model for capacity management based on different costing models (ABC and TDABC). A generic model has been
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
1. Introduction
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
1. Introduction
optimization might
Fine blanking is ahide
veryoperational
economicalinefficiency.
manufacturing process for the production of high quality parts from sheet metal.
© 2017
Fine The Authors.
blanking is aPublished
very by Elsevier
economical B.V.
manufacturing
The die roll height is a deficit of the sheared edge of process for theparts
fine blanked production of high quality
which reduces partssize
the usable fromof sheet metal.
the sheared
Peer-review
The die rollunder
heightresponsibility
is a deficit ofofthe scientific
the sheared committee
edge of of the
fine Manufacturing
blanked parts Engineering
which reducesSociety
the International
usable size ofConference
the sheared
edge and makes secondary finishing necessary [1]. Since the die roll height is an important quality attribute of fine
2017.
edge andparts,
makes secondary finishing necessarywith [1].the
Since
blanked a lot of research was conducted aimthe die roll height
of predicting is an important
and minimizing quality
the die attribute
roll height. of fine
Studying
blanked parts, a lot of research was conducted with the aim of predicting and minimizing the die roll height. Studying
Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency

1. Introduction
* Corresponding author. Tel.: +49 241 80-28039; fax: +49 241 80-22293.
* Corresponding
E-mail address:author. Tel.: +49 241 80-28039; fax: +49 241 80-22293.
J.Stanke@wzl.rwth-aachen.de
The cost
E-mail of idle
address: capacity is a fundamental information for companies and their management of extreme importance
J.Stanke@wzl.rwth-aachen.de
in modern©production
2351-9789 systems.
2018 The Authors. In general,
Published it isB.V.
by Elsevier defined as unused capacity or production potential and can be measured
in several©ways:
Peer-review
2351-9789 tons
underThe
2018 of production,
responsibility
Authors. of theby
Published available
scientific
Elsevier B.V.hours of the
committee manufacturing, etc.Conference
17th International The management of the idle capacity
on Metal Forming.
Peer-review under
* Paulo Afonso. responsibility
Tel.: +351 253 510of thefax:
761; scientific committee
+351 253 604 741 of the 17th International Conference on Metal Forming.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 17th International Conference on Metal Forming.
10.1016/j.promfg.2018.07.279
 Joachim Stanke et al. / Procedia Manufacturing 15 (2018) 570–577 571
2 Joachim Stanke et al./ Procedia Manufacturing 00 (2018) 000–000

the influence of the die chamfer shape in a fine blanking tool on the die roll height Kim et al. found out that the die
roll height decreases with decreasing die chamfer angle [2]. Based on this, Kim et al. investigated the effect of the V-
ring position on different corner shapes of fine blanked parts [3]. The authors’ conclusion was that the die roll height
increases with increasing V-ring distance. Liu et al. studied the influence of the part shape in fine blanking on the die
roll height and found out that convex part shapes increase the die roll height and concave shapes decrease the die roll
height [4]. Tang et al. succeeded in reducing the die roll height of an automotive part by developing a special die
design. The authors achieved this by setting the cutting edge on a special indenter along the edge of the die [5]. Luo
et al. successfully used an insertion block in a fine blanking tool to reduce the die roll height on an automotive part
[6]. The authors were able to reduce the die roll height by about 70 % with their modification. In those works only the
influence of a limited number of variables on the die roll height was investigated. However, the die roll height depends
on a large number of influencing variables with many nonlinear relationships. Fuchiwaki et al. determined the rela-
tionship between the die roll height and the material, material thickness, punch-die clearance, corner angle of a convex
corner shape and the corner edge radius [7]. The authors used an analytical approach to model those relationships. If
the number of influencing variables on the die roll height is increased further, traditional analytical approaches are
inappropriate for the modelling process, because it gets increasingly difficult to capture all the different interdepend-
encies with such an approach. With those approaches it is not possible to develop a model which is able to predict the
die roll height quantitatively for a large number of influencing variables.
A promising approach to predict output values for very complex nonlinear systems is machine learning. Artificial
neural networks are machine learning models which have already been successfully used to predict output variables
for fine blanking and shearing processes. Hambli developed an artificial neural network model to substitute FE simu-
lations after a training phase and used the developed model to optimize the die clearance of a shearing process [8].
Djavanroodi et al. successfully predicted the die roll on a fine blanked workpiece depending on the V-ring geometry,
the blank holder force and the counter punch force using an artificial neural network model [9]. For the training of the
artificial neural network model, they also used FE simulation data. Al-Momani et al. developed a model for the pre-
diction of burr height in a shearing process using artificial neural networks and multiple regression analysis [10]. They
found that the artificial neural networks yielded better results and concluded that this is because artificial neural net-
works are better suited to detect hidden non-linear relationships. Yin et al. trained an artificial neural network with FE
simulation data of a fine blanking process and succeeded in predicting the die wear over the entire service life of the
tool [11]. From the artificial neural network, they were able to derive the inherent law between the process parameters
and the die wear. The results of the model matched very well with experimental data.

(a) Tool with die radius (b) Tool with die chamfer
Punch ��� Blank Punch ��� Blank
�� holder �� holder
�� ��

ℎ �� ℎ ��

� �

ℎ �� ℎ ��
��� �� ��� ℎ�
Counter Counter ℎ� �
punch �� Die punch � Die

Fig. 1 Fine blanking tool with (a) die radius and (b) die chamfer.

However, in those works only a limited number of influencing variables were considered, therefore some key in-
terdependencies are still missing. The aim of this work is to model the die roll height during fine blanking of 16MnCr5
(DIN 1.7131, AISI/SAE 5115) considering the interdependencies of the die chamfer height ℎ� or die radius �� , the
number of V-rings and the V-ring heights ℎ�� , ℎ�� , the V-ring position �� , the workpiece thickness �, the blank holder
572 Joachim Stanke et al. / Procedia Manufacturing 15 (2018) 570–577
Joachim Stanke/ Procedia Manufacturing 00 (2018) 000–000 3

force ��� , the counter punch force ��� and the cutting velocity �� using an artificial neural network, cf. Fig. 1. How-
ever, machine learning algorithms need big amounts of experimental data, which is very time and cost intensive to
supply if provided with experiments alone. Therefore, a hybrid approach using experiments and FE simulations is
within the scope of this contribution. FE modelling of a fine blanking process makes it possible to create lots of scatter-
free data. Hence, this data of a validated FE model is used to train machine learning models and derive an optimal
model in order to reduce the die roll height. The required amount of training data for the models will be determined
using learning curves. The number of neurons and hidden layers for the artificial neural network will be variated and
an optimal architecture for the model will be derived from the results. Additionally, the die roll height is modelled
using support vector machines and also conventional statistical regression models. The result of this contribution is a
comparison of the derived models regarding their prediction ability.

2. FE modelling

In order to generate the training and test data a rotationally symmetric fine blanking process was modelled using
FE software Abaqus 6.14. For the time integration, an explicit scheme was used since explicit time integration schemes
are more stable in large deformations. The fine blanking tool consists of a punch, a counter punch, a blank holder and
a die, cf. Fig. 2(a).

Fig. 2. (a) Structure of FE model of fine blanking process; (b) Simulated fine blanking process at 2 mm cutting depth; (c) Part produced by fine
blanking for validation of FE model.

The fine blanking process was modelled temperature-coupled since heating up in the shear zone occurs during the
fine blanking because of dissipated forming energy. For the discretization of the FE model axisymmetric elements of
type CAX4RT with reduced integration were used. For the shear zone of the workpiece an element size of 0.05 mm
was used. The element size was determined using a convergence analysis of the dependence between the die roll
height and the element size [12]. At a value of 0.05 mm element size in the shear zone the die roll height is almost
independent from the element size. For the remaining parts, a coarser discretization was chosen. Since large defor-
mations occur during the fine blanking simulation, Arbitrary Euler Lagrange remeshing for the shear zone of the
workpiece was used. The fine blanking process was simulated in two steps. In the first step either the die or the blank
holder and die (depending on the number of V-rings used) are moved with constant speed �� = 50 mm/s until the V-
rings are completely pressed into the workpiece. The punch is kept fixed in this step and on the counter punch the
counter punch force ��� is applied according to the experimental plan, cf. Table 1. In the second step the die is kept
fixed and on the blank holder the blank holder force ��� is applied according to the experimental plan. On the counter
punch still acts the counter punch force ��� and the punch is moved with cutting speed �� until 2 mm cutting depth,
cf. Fig. 2(b). It was confirmed that at 2 mm cutting depth, the die roll is already completely formed. The tools of the
model were modelled as rigid bodies. The workpiece was modelled elastic-plastic using analytical Hensel Spittel flow
curve modelling. The modelled workpiece material was AISI/SAE 5115. For contact modelling, a penalty algorithm
and a COULOMB friction model with a coefficient of friction � = 0.1 was used. For the validation of the model 20 fine
 Joachim Stanke et al. / Procedia Manufacturing 15 (2018) 570–577 573
4 Joachim Stanke et al./ Procedia Manufacturing 00 (2018) 000–000

blanking experiments were performed with a fixed parameter set, cf. Fig. 2(c). After the fine blanking experiments,
the die roll height was determined and averaged. The result was compared with the simulation and it was found that
the deviation between simulation and experiment is only 4.1%. Since the simulated results are in very good agreement
with the experimental results, the FE model is assumed to be validated.

Table 1. Experimental plan.

Die chamfer Die radius �� V-ring height V-ring posi- Blankholder Counter punch Cutting speed Workpiece
ℎ� [mm] [mm] ℎ�� / ℎ�� tion �� [mm] force ��� force ��� [kN] �� [mm/s] thickness �
[mm] [kN] [mm]
0.05 0.8 / 1.2 2.8 300 25 10 4
0.3 0.3 0.0 / 0.8 3.5 450 90 50 6
0.6 0.6 0.0 / 0.0 600 10

After the validation of the FE model 900 simulations were performed. The total number of simulations is derived
from every possible combination of the variables found in the experimental plan shown in Table 1. For every simula-
tion the die roll height was determined and the result was written together with the used variables into a CSV file.
After this the CSV file was read in for training of the predictive models.

3. Predictive modelling

For the modelling process Python was used as the programming language. Libraries for the machine learning and
regression modelling were scikit-learn and Keras with Tensorflow backend. In total 900 data sets from the FE simu-
lation were used. Every data set consisted of the used die chamfer height or die radius, V-ring heights, the V-ring
position, the workpiece thickness, the blank holder force, the counter punch force and the cutting velocity for the FE
simulation as input valued and the simulated die roll height as the desired output of the model. Before the data was
used for training and testing, a preprocessing of the data was performed. The data was standardized and scaled to unit
variance. This is a requirement for many Machine Learning and regression methods. If not stated otherwise 720 data
sets were used for the training of the models and 180 were used for the testing. Those numbers represent 80 % and
20 % of the total data set size respectively.

3.1. Modelling die roll height using artificial neural networks

First the die roll height is modelled using artificial neural networks. Fully connected feed forward artificial neural
networks with back propagation algorithm were used for the modelling. For the determination of an optimal artificial
neural network in predicting the die roll height it is necessary to determine the architecture, and the hyperparameters
of the artificial neural network. For the determination of the architecture and the hyperparameters 39 different archi-
tectures were tested.
0,0012
Mean squared error MSE [-]

Lowest error
0,001
0,0008
artificial neural

artificial neural

artificial neural

0,0006
Test data
Three layer

0,0004
One layer

Two layer

Training data
networks

networks

networks

0,0002 Trend line test data

Trend line training data
0
5/0/0
10/0/0
20/0/0
5/5/0
5/10/0
5/20/0
10/5/0

20/5/0

5/5/5

5/10/5

5/20/5

10/5/5

20/5/5
5/5/10
5/5/20
10/10/0
10/20/0

20/10/0
20/20/0

5/10/10
5/10/20

5/20/10
5/20/20

10/5/10
10/5/20
10/10/5

10/20/5

20/5/10
20/5/20
20/10/5

20/20/5
10/10/10
10/10/20

10/20/10
10/20/20

20/10/10
20/10/20

20/20/10
20/20/20

Number of neurons per layer ��,� / ��,� / ��,� [-]

Fig. 3. Dependency of mean squared error on artificial neural network architecture.

574 Joachim Stanke et al. / Procedia Manufacturing 15 (2018) 570–577
Joachim Stanke/ Procedia Manufacturing 00 (2018) 000–000 5

The tested architectures include artificial neural networks with up to 3 layers, consisting of 5, 10 or 20 neurons,
each. The results are shown in Fig. 3. For the evaluation of the artificial neural networks the mean squared error
between predicted die roll height and simulated die roll height on the test and training data was used. 10 % of the
training data was used for cross validation. For every artificial neural network ten different distributions of training
and test data were used and the error was averaged in order to exclude effects governed from specific training and test
data distributions. From the results it is observed that the error of the predictions based on the test data does not
generally decrease for deeper or wider artificial neural networks. On the training data the error slightly decreases for
deeper and wider artificial neural networks. The reason for this is that the deeper and wider artificial neural networks
fit the training data better but the ability to generalize does not increase. This implies that the functional dependencies
between the studied parameters is not complex enough to make deep and wide artificial neural networks necessary.
The best result on the test data was achieved with an artificial neural network with 2 layers and 10 neurons in the first
layer and 20 in the second layer. For every single architecture the optimal hyperparameters were determined using
grid search. The hyperparameter space for the grid search is shown in Table 2.

Table 2. Artificial neural network hyperparameter space for determination of optimal hyperparameter using grid search. Underlined entries
yielded lowest mean squared error.

Activation function Optimizer Initializer Batch size Epochs

Sigmoid Stochastic gradient Uniform 1 150
descent/ Mini-batch
gradient descent/
Batch gradient de-
scent
Tangens hyperboli- Adam Glorot uniform 32 200
cus
648

For the activation function, optimizer and initializer the most often used and best suited options were chosen. In
case of the gradient descent optimizer the specific version was chosen according to the batch size. For the batch size
the resulting gradient descent scheme is the stochastic gradient descent scheme, for the batch size of 32 the mini-batch
gradient descent scheme and for the batch size of 648 the batch gradient descent scheme were used. The hyperparam-
eters which achieved the best results are highlighted in Table 2.

3.2. Modelling die roll height using support vector machines

The second approach to model the die roll height in fine blanking was using support vector machines. For the
kernel function the radial basis function was chosen, since the right choice of hyperparameters radial basis function
kernel perform better than a linear kernel [13]. The hyperparameters used for the support vector machines grid search
are shown in Table 3.

Table 3. Support vector machine hyperparameter space for determination of optimal hyperparameter using grid search. Underlined entries yielded
lowest mean squared error.

Penalty parameter � �-insensitivity parameter �

1 0.00111033
0.797508432791 0.00284799
0.00854398

For the penalty parameter � a value of 1 can already be a good choice. CHERKASSKY et al. proposed choosing the
penalty parameter C according to the following equation [14]:

� = max���� + 3�y�, ��� − 3�y ��. (1)

 Joachim Stanke et al. / Procedia Manufacturing 15 (2018) 570–577 575
6 Joachim Stanke et al./ Procedia Manufacturing 00 (2018) 000–000

In this equation �� denotes the mean value of the given model outputs, in this case the die roll height and �� denotes
the standard deviation of the given model outputs. Further, the authors proposed for small data sets that the following
relation yields good results for � [14]:
�
�=� . (2)
√�

In this equation � denotes the number of elements in the training data set and τ is a factor which has to be deter-
mined empirically. For bigger data sets the following definition for a good choice of the penalty parameter � was
found [14]:

�� �
� = ��� . (3)
�

With an empirical study, the authors showed that a value for � = 3 yields good results in most cases. For the
determination of the optimal values for the �-insensitivity parameter �, three � values calculated with Eq. (2) and (3)
were used. The first � value was calculated with Eq. (2) and � set to 1, the second � value was calculated with Eq. (3)
and � set to 1 and the third � value was calculated with Eq. (3) and � set to 3. For the penalty parameter � a value of
1 and a value calculated with Eq. (1) was used. The performed grid search showed that Eq. (3) with � set to 3 in
combination with a penalty parameter C calculated with Eq. (1) yielded the lowest mean squared error.

3.3. Modelling die roll height using linear and quadratic regression

After the die roll height in fine blanking was modelled using machine learning methods, die roll height is being
modelled using statistical methods. The chosen methods are linear and quadratic regression. As the input space of the
desired predictive model was multidimensional, the multi-linear and multi-quadratic regression was selected. The
coefficients of the linear and quadratic regression model are determined by minimizing mean squared error. No hy-
perparameters have to be determined for the linear and quadratic regression. The aim of modelling die roll height
using regression models is to compare the quality of those models with those gained by means of machine learning
methods.

3.4. Results and comparison of methods

The quality of the developed models was studied by means of observing the coefficient of determination � � of the
developed models. The coefficient of determination was studied on the test and training data set. Additionally, differ-
ent fractures of training data size was used. In total a number of 900 data sets of input variables and simulated die roll
heights were available. From this 720, 540, 360, 180, 90, 45, and 23 were used to train the models. The aim was to
determine how much of the data is necessary to model the studied problem.
Artificial neural network results Support vector machine results
[-]

[-]

1 1
Coefficient of determination

Coefficient of determination

0,8 0,8

0,6 Test data set 1 0,6 Test data set 1

Test data set 2 Test data set 2
0,4 Test data set 3 0,4 Test data set 3
Training data set 1 Training data set 1
0,2 Training data set 2 0,2 Training data set 2
Training data set 3 Training data set 3
0 0
23 45 90 180 360 540 720 23 45 90 180 360 540 720
Size of data set used for Training �� [-] Size of data set used for Training �� [-]

Fig. 4. Learning curves for modelling of die roll height using artificial neural networks and support vector machines.
576 Joachim Stanke et al. / Procedia Manufacturing 15 (2018) 570–577
Joachim Stanke/ Procedia Manufacturing 00 (2018) 000–000 7

To capture the influence of different distributions, three different data sets were randomly selected from the com-
plete data set. For every model in this chapter, the same data sets were used. The results for the artificial neural network
and support vector machine modelling are shown in Fig. 4. The artificial neural network used in this part is the previ-
ously determined optimal one. Observing the results it can be seen that artificial neural networks yield good results
regarding the coefficient of determination. The coefficients of determination of the artificial neural network model on
the test data sets are already above a value of 80 for small training data sizes of 45 and above. Furthermore the results
are almost independent of the chosen data distribution. The highest coefficient of determination is reached with a
training size of about 540 and has a value of about 95 which shows good accuracy of the derived model. In comparison
support vector machines show similarly good coefficients of determination � � but perform a little worse for lower
training data sizes. It can be observed that for both, artificial neural networks and support vector machines the coeffi-
cient of determination � � converges and the for greater training data sizes no increase in model accuracy can be ex-
pected. The remaining error between predictions and simulated values can be explained by the fact that the training
data is not completely error-free. The results from the regression models are shown in Fig. 5.
Linear regression results Quadratic regression results
[-]

[-]
1 1
Coefficient of determination

Coefficient of determination
0,8 0,8

0,6 Test data set 1 0,6 Test data set 1

Test data set 2 Test data set 2
0,4 Test data set 3 0,4 Test data set 3
Training data set 1 Training data set 1
0,2 Training data set 2 0,2 Training data set 2
Training data set 3 Training data set 3
0 0
23 45 90 180 360 540 720 23 45 90 180 360 540 720
Size of data set used for Training �� [-] Size of data set used for Training �� [-]

Fig. 5. Learning curves for modelling of die roll height using linear and quadratic regression.

The results show that linear regression does not need big amounts of data to be able to generalize from them.
However, the best results remain below a coefficient of determination value of 90. This implies that the dependencies
between the observed variables and the die roll height in fine blanking can not be approximated linearly. Quadratic
regression performed much better with big data sets with a size of 360 and above but can perform poorly if the training
data is not sufficient. The reason for the worse performance on smaller data sets is founded in the determination of
more unknowns in quadratic regression. After this the results of all methods are compared in Fig. 6. For this compar-
ison the results of the three data sets were averaged.
Results on test data
[-]

1
Coefficient of determination

0,8

0,6

0,4 Linear regression

Quadratic regression
0,2 Support vector machine
Artificial neural network
0
23 45 90 180 360 540 720
Size of data set used for Training �� [-]

Fig. 6. Comparison of machine learning methods and statistical regression models.

It can be observed that linear regression generally performs worse than the machine learning methods. It performs
better than quadratic regression but only for data sets with a size below 360. Support vector machines and artificial
 Joachim Stanke et al. / Procedia Manufacturing 15 (2018) 570–577 577
8 Joachim Stanke et al./ Procedia Manufacturing 00 (2018) 000–000

neural networks perform almost equally well and yield good results already starting with training data set sizes of 45.
Quadratic regression performs poorly in comparison to the other methods on training data sizes below 180 and below
but on training data sizes of 360 and above the prediction ability is almost the same as the one gained from the mod-
eling with the machine learning models artificial neural networks and support vector machines. This implies that the
relationship between the observed variables and the die roll height is almost quadratic and that hence artificial neural
networks and support vector machines can not approximate the behavior better than quadratic functions.

4. Discussion and Outlook

It was shown that artificial neural networks can be used to model die roll height in fine blanking with very high
accuracy and that good results can already be obtained with smaller data sets. Also the necessary hyperparameter and
architecture for the optimal modelling of the die roll height with artificial neural networks were shown. Similar results
were obtained using support vector machines. Modelling the die roll height using quadratic regression also yielded
good results for very large training data but performed poorly with smaller data. With linear regression, it was not
possible to obtain a model similar in accuracy to that obtained by machine learning.
At this point primarily data of an experimentally validated FE model was used to train the predictive models.
However, a certain error remains between FE simulation and experiment. In future work it will be studied how exper-
imental data can be used to enhance the pre conditioned models and reduce the remaining error between FE simulation
and experiment.

Acknowledgements

This work was supported by the Federal Ministry for Economical Affairs and Energy (BMWi) within the project
“Mittelstand 4.0 – Digitale Produktions- und Arbeitsprozesse” and the German Research Foundation (DFG).

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