Evaluation of control strategies in forming processes

Technische Universität Darmstadt, Institute for Production Engineering and Forming Machines, 64287 Darmstadt, Germany

^a Corresponding author: e-mail: calmano@ptu.tu-darmstadt.de

Abstract

Products of forming processes are subject to quality fluctuations due to uncertainty in semi-finished part properties as well as process conditions and environment. An approach to cope with these uncertainties is the implementation of a closed-loop control taking into account the actual product properties measured by sensors or estimated by a mathematical process model. Both methods of uncertainty control trade off with a financial effort. In case of sensor integration the effort is the cost of the sensor including signal processing as well as the design and manufacturing effort for integration. In case of an estimation model the effort is mainly determined by the time and knowledge needed to derive the model, identify the parameters and implement the model into the PLC. The risk of mismatch between model and reality as well as the risk of wrong parameter identification can be assumed as additional uncertainty (model uncertainty). This paper evaluates controlled and additional uncertainty by taking into account process boundary conditions like the degree of fluctuations in semi-finished part properties. The proposed evaluation is demonstrated by the analysis of exemplary processes.