Optimisation of cutting processes using intelligent cutting tools

ended

The amount of high strength steel grades in the automotive industry has been increasing because of higher safety demands in the context with energy savings and CO2-reduction connected with the demand on light weight car body constructions. The consequences are increasing wear problems at cutting tools in the finishing departments of the European steel industry and other steel processing fields, especially the automotive industry. The project IntellCutProcess will investigate two prevalent technologies in the field sheet metal cutting: (1) the punching as well as (2) the shearing of steel sheet. The objectives of IntellCutProcess shall be achieved by means of a holistic approach comprising the investigation/measurement of the tool wear, the influenced process parameters (cutting force, die clearance, shear angle, etc.), the optimisation of tool (material and wear protective coating), the development of sensor-equipped (intelligent) tools and the development of a predictive wear warning system. The project objectives will be achieved by developing a multi-component solution with a wear predictive strategy consisting of: - a wear warning system • optical analysis tool (cut edge evaluation), • measurements and analysis of important process parameters, • software tool for wear prediction, - the use of adapted tool material and functional wear protective coatings, - the use of an optimised surface topography of the tools - the adaptation of tool geometries and process conditions. - the modelling of punching and shearing processes The following technical and economic advantages can be expected: - Increased tool lifetime and thus reduced tool costs, - Reduction of production waste due to poor cut edge quality, - Reduction of press line downtime due to tool breakage - Optimisation of maintenance intervals through condition-based maintenance, - Increase of product quality, - Improvement of process understanding.