Developing a Self-optimizing Forming System

AbstractThe forming process is nonlinear, and it is difficult to clearly understand forming mechanism and deformation law of workpiece during forming process. In addition, the disturbances such as inhomogeneous material of workpiece, high temperature, roller wear, etc., often occur during forming. These disturbances cause the inaccuracy of the pulley geometric shape and reduction of the product quality. To handle this challenge, first a 3D-FE simulation was executed to investigate the deformation behavior of workpiece and to find the forming parameters. In the next step, a self-optimizing strategy was developed as a control system to improve the product quality. This self-optimizing approach is being practiced in the real forming machine system for validating the efficiency of the proposed strategy