Method and computer system for characterizing a sheet metal part

Abstract

A method for the characterization of a sheet metal forming product uses the correlation of material flow data to a priori calculated or measured data. It determines whether the product falls within the acceptable production limits in terms of quality, areas of potential defects and an approximation of the process parameters prevailing during its production. The characterization is performed in real-time during production, tool deployment or try-out. The method includes the steps of: providing physical dimensions of an actual sheet metal part; a feature extractor computing, from these physical dimensions, a measured material flow metric representative of the geometry of the part after the forming operation; and a matching unit determining, from reference data and the measured material flow metric, a matching forming operation data set whose associated simulated material flow metric most closely matches the measured material flow metric.

The invention claimed is: 
     
       1. A method for characterizing a sheet metal part, the method comprising the steps of:
 a sensing operation providing physical dimensions of an actual sheet metal part before, during and/or after a forming operation; 
 a feature extractor computing, from these physical dimensions, a measured material flow metric, the measured material flow metric being representative of a geometry of the actual sheet metal part after the forming operation; 
 retrieving, from a computer readable data storage device, reference data that represents the results of a set of simulations of the forming operation, each simulation being associated with a forming operation data set that characterizes the simulation, and a simulated material flow metric that is a result of the simulation; 
 a matching unit determining, from the reference data and the measured material flow metric, a matching forming operation data set whose associated simulated material flow metric most closely matches the measured material flow metric and 
 outputting, on a display device or on the actual sheet metal part, a visual representation of data of the matching forming operation data set or putting a human or machine readable marking on the actual sheet metal part representative of the forming operation data set. 
 
     
     
       2. The method of  claim 1 , wherein the reference data comprises at least one of a simulation data set and class definition data and mapping information; wherein
 the simulation data set comprises a plurality of forming operation data sets and associated simulated material flow metrics, the forming operation data sets comprising at least one of: process parameters of the forming operation, forming operation result data and a geometry of a simulated sheet metal part, and the simulated material flow metric being representative of the geometry of a flange area of the simulated sheet metal part after the forming operation; and 
 the class definition data defines classes within the simulated material flow metrics; 
 the mapping information defines one or more mapping functions, defining a mapping from material flow metrics to forming operation data sets, with either a set of one or more mapping functions being defined globally over all material flow metrics, or a set of one or more local mapping functions for each class, being defined over the material flow metrics corresponding to that class. 
 
     
     
       3. The method of  claim 1 , wherein the matching forming operation data set comprises at least one of:
 process parameters of the forming operation; 
 the geometry of the simulated sheet metal part after the forming operation; 
 state variables of the simulated sheet metal part after the forming operation; 
 areas of defects of the part shaped by the forming process; and 
 qualitative or quantitative information on how to change the process parameters of a forming operation in order to achieve a desired process performance. 
 
     
     
       4. The method of  claim 1 , wherein the matching unit performs the steps of:
 given the measured material flow metric, determining a class into which this measured material flow metric falls; 
 returning, as matching forming operation data set, one of the forming operation data sets with this class. 
 
     
     
       5. The method of  claim 1 , wherein the matching unit performs the step of:
 returning, as matching forming operation data set, a matching forming operation data set inferred from the measured material flow metric by means of a mapping function. 
 
     
     
       6. The method of  claim 1 , wherein the measured material flow metric and the simulated material flow metrics are either flange or a draw-in distribution or a combination of both. 
     
     
       7. The method of  claim 1 , comprising providing a data storage device comprising stored non-transitory computer program code which, when executed performs the sensing, the computing, the retrieving, and the matching. 
     
     
       8. The method of  claim 1 , comprising providing a computer system for characterizing the sheet metal part, the computer system comprising a data processor, the computer system being configured and programmed to execute the sensing, the computing, the retrieving, and the matching. 
     
     
       9. The method of claim  8  1, comprising providing a sensing device arranged to provide physical dimensions of the actual sheet metal part after the forming operation. 
     
     
       10. A method for generating reference data for characterizing a sheet metal part, the method comprising the steps of:
 a) providing forming operation result data, the forming operation result data comprising at least a geometry of a simulated sheet metal part after the forming operation; 
 b) a postprocessor computing, from a forming operation result data, a simulated material flow metric, the simulated material flow metric being representative of the geometry of the simulated sheet metal part after the forming operation; 
 c) storing, in a non-transitory computer readable storage medium, the simulated material flow metric and a forming operation data set, the forming operation data set comprising at least one of the process parameters and the forming operation result data; 
 d) repeating the preceding steps several times with different forming operation result data and storing, in a computer readable data storage device, in each case the forming operation data set and the associated simulated material flow metric, the entirety of forming operation data sets and associated simulated material flow metrics constituting a simulation data set; 
 e) computing and storing, in the computer readable data storage device, mapping information that defines a relationship between material flow metrics and forming operation data sets and 
 outputting, on a display device or on an actual sheet metal part, a visual representation of data of at least one of the forming operation data sets or putting a human or machine readable marking on the actual sheet metal part representative of at least one of the forming operation data sets. 
 
     
     
       11. The method of  claim 10 , wherein the step of providing forming operation result data comprises the steps of:
 f) providing a set of simulation parameters, the simulation parameters defining at least process parameters of the forming operation performed on the sheet metal part; 
 g) a numerical simulator simulating execution of the forming operation on the sheet metal part, the forming operation being characterized by the simulation parameters, and the numerical simulator thereby computing the forming operation result data; 
 wherein the repeating of step a) for providing forming operation result data is done using different sets of simulations parameters. 
 
     
     
       12. The method of  claim 10 , comprising the further steps of:
 h) a class extractor analysing the material flow metrics generated by the several simulations and identifying a plurality of classes within these simulated material flow metrics; and 
 i) storing, in the computer readable data storage device, class definition data defining these classes, wherein the mapping information associates one or more simulation data set with each class, for further use as reference data for characterizing the sheet metal part. 
 
     
     
       13. The method of one of  claim 10 , wherein
 the mapping information defines one or more mapping functions, defining a mapping from material flow metrics to forming operation data sets, with either a set of one or more mapping functions being defined globally over all material flow metrics, or a set of one or more local mapping functions for each class of a plurality of classes within the material flow metrics, the local mapping function being defined over the material flow metrics corresponding to that class. 
 
     
     
       14. The method of  claim 10 , comprising providing a data storage device comprising stored non-transitory computer program code which, when executed on a computer system, performs the providing, the computing, the storing, and the repeating. 
     
     
       15. A method for characterizing a sheet metal part, the method comprising the steps of:
 a sensing operation providing physical dimensions of an actual sheet metal part before, during and/or after a forming operation;   a feature extractor computing, from these physical dimensions, a measured material flow metric, the measured material flow metric being representative of the geometry of the actual sheet metal part after the forming operation;   retrieving, from a computer readable data storage device, reference data that represents the results of a set of simulations of the forming operation, each simulation being associated with a forming operation data set that characterizes the simulation, and a simulated material flow metric that is a result of the simulation;   a matching unit determining, from the reference data and the measured material flow metric, a matching forming operation data set whose associated simulated material flow metric most closely matches the measured material flow metric, wherein the matching forming operation data set comprises at least one of:   process parameters of the forming operation;   state variables of the simulated sheet metal part after the forming operation;   based on at least one of process parameters and state variables of the matching forming operation data set, modifying process parameters; and   performing a forming operation with the modified process parameters to produce a further sheet metal part.    
     
     
       16. The method of claim 15, wherein the reference data comprises at least one of a simulation data set and class definition data and mapping information; wherein
 the simulation data set comprises a plurality of forming operation data sets and associated simulated material flow metrics, the forming operation data sets comprising at least one of: process parameters of the forming operation, forming operation result data and the geometry of a simulated sheet metal part, and the simulated material flow metric being representative of the geometry of the flange area of the simulated sheet metal part after the forming operation; and   the class definition data defines classes within the simulated material flow metrics;   the mapping information defines one or more mapping functions, defining a mapping from material flow metrics to forming operation data sets, with either a set of one or more mapping functions being defined globally over all material flow metrics, or a set of one or more local mapping functions for each class, being defined over the material flow metrics corresponding to that class.    
     
     
       17. The method of claim 15, comprising the further step of outputting, on a display device or on the actual sheet metal part, a visual representation of data of the matching forming operation data set or putting a human or machine readable marking on the actual sheet metal part representative of the forming operation data set.  
     
     
       18. The method of claim 15, wherein the matching forming operation data set comprises at least one of:
 the geometry of the simulated sheet metal part after the forming operation;   areas of defects of the part shaped by the forming process;   qualitative or quantitative information on how to change the process parameters of a forming operation in order to achieve a desired process performance.    
     
     
       19. The method of claim 15, wherein the matching unit performs the steps of:
 given the measured material flow metric, determining a class into which this measured material flow metric falls;   returning, as matching forming operation data set, one of the forming operation data sets with this class.    
     
     
       20. The method of claim 15, wherein the matching unit performs the step of:
 returning, as matching forming operation data set, a matching forming operation data set inferred from the measured material flow metric by means of a mapping function.    
     
     
       21. The method of claim 15, wherein the measured material flow metric and the simulated material flow metrics are either the flange or the draw-in distribution or a combination of both.  
     
     
       22. The method of claim 15, comprising providing a data storage device comprising stored non-transitory computer program code which, when executed performs the sensing, the computing, the retrieving, and the matching.  
     
     
       23. The method of claim 15, comprising providing a computer system for characterizing a sheet metal part, the computer system comprising a data processor, the computer system being configured and programmed to execute the sensing, the computing, the retrieving, and the matching.  
     
     
       24. The method of claim 23, comprising providing a sensing device arranged to provide physical dimensions of an actual sheet metal part after a forming operation.  
     
     
       25. The method of claim 15, comprising the step of
 using an evaluation of at least one of process parameters and state variables of the matching forming operation data set to do, during tryout or during production, at least one of:   accept or reject the part;   adjust the process and tools if the part is not acceptable.    
     
     
       26. The method of claim 15, comprising the steps of
 during production, based on at least one of process parameters and state variables of the matching forming operation data set, determining potential defects on the part; and   providing feedback to operators or equipment in order to return a process that drifts away from acceptable limits back under control.    
     
     
       27. The method of claim 15, comprising the step of
 during production, providing for digital feedback for closed loop control of equipment at least one of additional quality control metrics, statistical information and advisory data.    
     
     
       28. The method of claim 27, comprising the step of
 performing closed loop control of equipment based on the at least one of additional quality control metrics, statistical information and advisory data.    
     
     
       29. The method of claim 28, comprising the step of
 performing a further forming operation to produce a further sheet metal part.    
     
     
       30. The method of claim 15, comprising the steps of
 providing for an operator at least one of additional quality control metrics, statistical information and advisory data;   displaying, on a display device, the at least one additional quality control metrics, statistical information and advisory data.    
     
     
       31. The method of claim 15, comprising providing a data storage device comprising stored non-transitory computer program code which, when executed on a computer system, performs the providing, the computing, the retrieving, and the matching.  
     
     
       32. A method for producing sheet metal parts, the method comprising the steps of:
 producing an actual sheet metal part by a forming operation;   a sensing operation providing physical dimensions of the actual sheet metal part before, during and/or after the forming operation;   a feature extractor computing, from these physical dimensions, a measured material flow metric, the measured material flow metric being representative of the geometry of the actual sheet metal part after the forming operation;   retrieving, from a computer readable data storage device, reference data that represents the results of a set of simulations of the forming operation, each simulation being associated with a forming operation data set that characterizes the simulation, and a simulated material flow metric that is a result of the simulation;   a matching unit determining, from the reference data and the measured material flow metric, a matching forming operation data set whose associated simulated material flow metric most closely matches the measured material flow metric, wherein the matching forming operation data set comprises at least one of:   process parameters of the forming operation; and   state variables of the simulated sheet metal part after the forming operation,   based on at least one of process parameters and state variables of the matching forming operation data set, modifying process parameters; and   performing a further forming operation with the modified process parameters to produce a further sheet metal part.    
     
     
       33. An apparatus for characterizing a sheet metal part, comprising:
 a sensing device arranged to provide physical dimensions of an actual sheet metal part before, during and/or after a forming operation;   a feature extractor arranged to compute, from these physical dimensions, a measured material flow metric, the measured material flow metric being representative of the geometry of the actual sheet metal part after the forming operation;   a computer readable data storage device arranged to allow retrieving of reference data that represents the results of a set of simulations of the forming operation, each simulation being associated with a forming operation data set that characterizes the simulation, and a simulated material flow metric that is a result of the simulation;   a matching unit arranged to determine, from the reference data and the measured material flow metric, a matching forming operation data set whose associated simulated material flow metric most closely matches the measured material flow metric, wherein the matching forming operation data set comprises at least one of:   process parameters of the forming operation;   state variables of the simulated sheet metal part after the forming operation; and   a unit arranged to:   based on at least one of process parameters and state variables of the matching forming operation data set, modify process parameters; and   perform a forming operation with the modified process parameters to produce a further sheet metal part.