The deep drawing process, especially when dealing with high drawing depths and small radii, presents a significant challenge in metal forming. Inadequate material flow during deep drawing can result in thinning and part fractures, while excessive material flow can lead to unwanted folds.
The material left after the forming process, often referred to as the flange or drawing edge, has a direct impact on the quality of the part. Schuler has thus developed a drawing edge monitoring system that facilitates the real-time assessment of part quality.
Michael Werbs, Director of Edge Solutions, explains:
“The number one priority for our customers is reducing scrap – not just to save costs, but increasingly also to meet sustainability goals. Schuler is making an important contribution to this with its new development”
This application is already in use at the Smart Press Shop, a joint venture between Porsche and Schuler located in Halle (Saale).
By employing a forming simulation, the drawing edge at critical points can be pre-determined and compared to values obtained in practice. The related data, along with a unique part identification number, are stored in a database. Based on these insights, adjustments to the process or modifications to the oiling and drawing cushion forces can be implemented even before visible quality issues like cracks or folds appear.
Previously, specialized dies with costly material flow measurement systems integrated into them were required, along with additional connections. Schuler's drawing edge monitoring system relies on cameras positioned in the press space, making it independent of specific dies and capable of monitoring the drawing process in any die used on the press. In a fraction of a second, the system provides feedback on whether a good part has been produced or not.