TY - GEN AU - Afsahnoudeh, Reza AU - Holzmüller, Maik AU - Bader, Fabian AU - Homberg, Werner AU - Kenig, Eugeny Y. ID - 28941 TI - Numerische Untersuchung von Oberflächenstrukturierung zur Erhöhung der Effizienz von Kissenplatten-Wärmeübertragern ER - TY - CONF AB - High-strength wire materials are usually available as strip material which is further processed in a forming process (e.g. punch-bending). For storage and transport of the semi-finished wire to the customer, the material is wound onto coils. The manufacturing and coiling process introduces plastic deformations into the wire, which lead to undesirable residual stresses and wire curvature of the semi-finished product. These residual stresses and curvatures cause variations in the material properties of the semi-finished product, which have a negative impact on the subsequent product quality. Straightening machines are used to compensate the residual stresses and the curvature in the wire. At the beginning of the straightening process, the straightening machines must be set up in such a way that residual stresses and curvatures are optimally compensated. This setup process is usually a manual and iterative process, where a lot of material is wasted until the optimal settings for the straightening machine are found.In order to reduce the amount of material waste, the operator must be supported in the setup process. In this context, a new and innovative setup assistance system was developed to support the operator during the setup process. The setup assistant system automatically detects the wire curvature by means of an optical measuring system. Based on the optically detected measuring points, the wire curvature is determined by a robust calculation algorithm. Based on a database built up through the carried out experimental and numerical research work, the optimum setting parameters for the straightening machine are suggested to the operator without lengthy trial and error. After confirmation by the operator, the roller settings are automatically adjusted by the mechatronic straightening machine. With the presented method, the conventional iterative setup procedure can be made more resource-efficient and a high straightening quality can be reproducibly achieved. AU - Bathelt, Lukas AU - Bader, Fabian AU - Djakow, Eugen AU - Henke, Christian AU - Trächtler, Ansgar AU - Homberg, Werner ID - 30263 TI - Innovative assistance system for setting up a mechatronic straightening machine ER - TY - CONF AB - Due to increasing globalization and rising quality requirements, the steel and metal processing industry is facing growing cost and innovation pressure. Not least because of their high lightweight potential, high-strength steel materials are meeting the growing material requirements of steel and metal processing in areas such as aerospace and medical technology. In particular, the tight tolerance limits of applicable shape and dimensional accuracies pose a challenge in the processing of high-strength steel strip materials. Improving the processability of high-strength steel materials through the use of straighteners with set-up assistance systems significantly increases the potential for competing with other materials such as aluminum or magnesium alloys. AU - Bader, Fabian AU - Bathelt, Lukas AU - Djakow, Eugen AU - Henke, Christian AU - Homberg, Werner AU - Trächtler, Ansgar ID - 30265 TI - An approach for an innovative 3d steel strip straightening machine for curvature and saber compensation ER - TY - CONF AU - Bathelt, Lukas AU - Bader, Fabian AU - Djakow, Eugen AU - Henke, Christian AU - Trächtler, Ansgar AU - Homberg, Werner ID - 33978 T2 - Fachtagung VDI MECHATRONIK 2022 TI - Mechatronische Richtapparate: Intelligente Richttechnik von hochfesten Flachdrähten ER - TY - JOUR AB - Higher quality requirements by customers demand higher precision and accuracy from manufacturing processes. Application oriented preparation of semi-finished materials is key for subsequent forming operations, therefore, straightening machines are employed. Straightening strengthens the material by increasing plastic deformation by means of strain hardening, resulting in undesirable reduction in formability when processing high strength materials, in particular. Conventional roll-type straightening machines process either bars or strips. This is achieved upon passing material between rolls arranged in two staggered rows. However, conventional straightening processes do not adapt to the local varying distortion of coiled strips. Innovative, self-correcting process control techniques, which adapt to the initial geometric characteristics of the strip, present a promising approach to fix this issue through optimization of the leveling process. Here, an innovative strategy to improve straightening of high strength steel materials (1.4310) is presented. This implements optimized leveling, adding minimal plastic deformation and, thus, strain hardening. To operate an intelligent straightening machine, a reliable online measurement of the surface defects is fundamentally essential. The MagnaTest, which is developed for material testing, is made feasible for such purposes after calibrating for curvature measurement. Preliminary results are promising in regards to measuring the curvature online, so that the following straightening process can be close loop controlled. The bending measurement is linked to open/closed loop control, therefore providing an optimal straightening result in regards to formability, leveling, and reduced strain hardening. AU - Bader, Fabian AU - Bathelt, Lukas AU - Djakow, Eugen AU - Homberg, Werner AU - Henke, Christian AU - Trächtler, Ansgar ID - 21633 JF - ESAFORM 2021 TI - Innovative Measurement Of Stress Superposed Steel Strip For Straightening Machines ER - TY - CHAP AB - Innovative self-correcting process control techniques which adapt to the initial geometric characteristics of the strip are a promising approach to fix the local varying distortion of coiled strips by optimizing the leveling process. This paper presents an innovative strategy to improve straightening of AHSS materials (1.4310). This implies optimized leveling, adding minimal plastic deformation, and, thus, strain hardening. Therefore, an “intelligent straightening machine” is being developed which will be presented. To operate an intelligent straightening machine a reliable online measurement of the surface defects is fundamentally essential. This paper describes an approach towards the measurement of a bent steel strip for an automatic straightening process. Therefore, various ways of measuring the bending curvature are investigated. Optical, tactile, and the electromagnetic induction testing MagnaTest are compared with each other. The bending measurement is linked to open-loop control, providing an optimal straightening result in regards of formability, leveling, and reduced strain hardening. AU - Bader, Fabian AU - Bathelt, Lukas AU - Djakow, Eugen AU - Homberg, Werner AU - Henke, Christian AU - Trächtler, Ansgar ID - 23385 SN - 2367-1181 T2 - Forming the Future TI - Self-optimized, Intelligent Open-Loop-Controlled Steel Strip Straightening Machine for Advanced Formability ER - TY - CONF AB - Abstract. Within the scope of this study, an intrinsically lubricated deep drawing die fabricated via laser beam melting (LBM) is investigated. In contrast to the common objective of generating highly dense LBM components, this work endeavors to achieve intended micro-scale porosity. By utilizing permeable structures, in-process closed-loop control of lubrication during the forming operations is feasible. Based on a modified AM scan strategy, the required filigree, porous structures can be generated. Thus, in the present work three permeable specimens are additively generated from the maraging steel 1.2709. The cylindrical specimens are then analyzed via light microscopy (LM), microcomputer tomography (microCT), and with regard to the oil throughput rate. Subsequently, an intrinsically lubricated, AM deep drawing tool die is manufactured and experimentally tested. The findings reveal interesting results for deep drawn specimens with AM deep drawing dies. AU - Bader, Fabian AU - Hengsbach, Florian AU - Hoyer, Kay-Peter AU - Homberg, Werner AU - Schaper, Mirko ID - 15024 T2 - PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019 TI - Intrinsically lubricated tool inserts for deep drawing applications generated by selective laser melting ER -