Innovative Online Measurement and Modelling Approach for Property-Controlled Flow Forming Processes

<jats:p>The production of complex multi-functional, high-strength parts is becoming increasingly important in the industry. Especially with small batch size, the incremental flow forming processes can be advantageous. The production of parts with complex geometry and locally graded material properties currently depicts a great challenge in the flow forming process. At this point, the usage of closed-loop control for the shape and properties could be a feasible new solution. The overall aim in this project is to establish an intelligent closed-loop control system for the wall thickness as well as the α’-martensite content of AISI 304L-workpieces in a flow forming process. To reach this goal, a novel sensor concept for online measurements of the wall thickness reduction and the martensite content during forming process is proposed. It includes the setup of a modified flow forming machine and the integration of the sensor system in the machine control. Additionally, a simulation model for the flow forming process is presented which describes the forming process with regard to the plastic workpiece deformation, the induced α’-martensite fraction, and the sensor behavior. This model was used for designing a closed-loop process control of the wall thickness reduction that was subsequently realized at the real plant including online measured feedback from the sensor system.</jats:p>