Man-in-the-loop control of flexible metal forming processes
Lead Research Organisation:
University of Cambridge
Department Name: Engineering
Abstract
Set in the overall research areas of novel manufacturing processes and materials engineering for metals and alloys, the project aims to develop man-in-the-loop control of flexible metal forming processes.
In the laboratory of Prof Julian Allwood at the University of Cambridge, various computer-controlled processes for shaping metal without fixed tooling have been designed and built. Several projects have been run working on the design of tool-paths with these machines, but due to the long solution times of finite element process models these have had limited success.
Nevertheless, craft workers - skilled manual operators - use related processes with great success. Therefore, this project aims to study and characterise the actions of skilled craftsmen using the equipment in the laboratory to inform new approaches to developing automatic control. In particular, an attempt will be made to build a tactile interface that reproduces the experience of metal spinning.
In the laboratory of Prof Julian Allwood at the University of Cambridge, various computer-controlled processes for shaping metal without fixed tooling have been designed and built. Several projects have been run working on the design of tool-paths with these machines, but due to the long solution times of finite element process models these have had limited success.
Nevertheless, craft workers - skilled manual operators - use related processes with great success. Therefore, this project aims to study and characterise the actions of skilled craftsmen using the equipment in the laboratory to inform new approaches to developing automatic control. In particular, an attempt will be made to build a tactile interface that reproduces the experience of metal spinning.
Organisations
People |
ORCID iD |
| Julian Allwood (Primary Supervisor) | |
| Iacopo Russo (Student) |
Studentship Projects
| Project Reference | Relationship | Related To | Start | End | Student Name |
|---|---|---|---|---|---|
| EP/N509620/1 | 01/10/2016 | 30/09/2022 | |||
| 1775345 | Studentship | EP/N509620/1 | 01/10/2016 | 30/09/2020 | Iacopo Russo |
| Description | My research focuses on (1) optimising control and (2) expanding the capabilities of a sheet metal forming technique called metal spinning. Metal spinning is used to make a variety of sheet metal products in the kitchenware, automotive and aerospace industry. It is advantageous over other techniques because it is more efficient in use of material and requires less investment to set up. The technique used to be performed manually by skilled craftsmen and today is only partly automated. Full automation would allow spinning to compete with other more estabilshed techniques, but it would require a fast and precise computer model. However, previous attempts to develop such model have failed. (1) To optimise control, I have installed a force-feedback device on a computer-controlled spinning machine, so that it could be controlled manually. I have invited craftsmen to operate the machine and I have recorded their actions. The key findings are: - Craftsmen have a reliable method to spin metal without tearing or wrinkling the product - Craftsmen can respond in real time to unexpected variations (1.1) I have also attempted another approach at optimising control. I have applied a force control approach instead of a displacement control. This has greatly simplified the design of process procedures needed to manufacture parts successfully. (2) To expand the capabilities of metal spinning, I have developed a method to produce parts with a more complex geometry than previously possible. Usually, metal spinning can only produce axisymmetric parts like pots and pans. I have developed a method to make square and oval parts, thus significanly extending the range of parts achievable. The key findings are: - Flexible asymmetric spinning can make a variety of parts with the same set of tools (no dedicated tooling required) - The thickness of the metal in the final part depends on the local curvature |
| Exploitation Route | I expect my findings to be used in the design of fully automated spinning machines which can make a variety of products without the need of dedicated tooling. These machines will be designed and built by companies and sold to sheet metal product manufaturers. |
| Sectors | Aerospace, Defence and Marine,Environment,Manufacturing, including Industrial Biotechology |
| URL | http://www.uselessgroup.org/ |
| Description | My research into flexible asymmetric metal spinning has shown partners in the automotive industry the potential that this technique has to prototype new sheet metal parts in a more cost efficient way than the current methods. Developing new parts for the body of automotive products is an expensive and slow process because the technique by which these are made, called sheet metal stamping, requires the manufactuing of new matching dies for every new part. Instead, in flexible metal spinning no dies are required, and multiple complex geometries can be manufactured freely, so that material, money and time are saved. My research established the process window in which flexible spinning is effective, and developed new methods to achieve successful parts. This will result in materials savings, thus reducing the overall environmental impact of making such products, and in cost savings for companies. |
| First Year Of Impact | 2018 |
| Sector | Manufacturing, including Industrial Biotechology |
| Impact Types | Cultural,Societal,Economic |