Fraunhofer Institute for Surface Engineering and Thin Films IST
Sensory thermoforming tool.
Sensor technology for metal forming
Challenge
In order to remain globally competitive, manufacturers need a deeper understanding of in-situ and real-time acquisition of process data. For example, parameters such as temperature and pressure are important for quality and optimization. The CORNET project SensoFut provides the answer for the collection of this data by means of a sensor coating for metal forming that can continuously collect information.
Solution
In this project, the Fraunhofer IST has developed a multisensory thin-film system which is applied directly to the surface of tools and modular inserts. It is a multilayer system which, in addition to local force and pressure measurement on complex-shaped surfaces, also enables local temperature measurement in different areas of the component and exhibits a high wear resistance.
Added value
The sensory tools for metal forming, in this case thermoforming and bending, were integrated into machines at the Fraunhofer IWU. They measure pressure and temperature distributions in contact with the sheet metal to be formed during the forming process. This makes it possible, for example, to avoid cracks and wrinkles in the thermoformed material.
Insights into the project
Sensory deep-drawing die with complete sensor system.
Schematic of the multifunctional coating systems.
Example of measurement results from
a deep-drawing process.
Colored representation of stressed force sensor structures F1 to F8 and temperature-sensitive meander structures T1 to T4 during the sheet-metal bending process.
Characteristic curves of the individual sensor structures during the forming process (sheet metal drawing force F = 10 kN, metal temperature T = 200 °C).
Funding reference
The results described were achieved within the SensoFut project (Sensorized Future - Sensing of temperature and pressure in harsh environments), on which the Fraunhofer IST worked in collaboration with the Fraunhofer Institute for Machine Tools and Forming Technology IWU and the Belgian research association Sirris. SensoFut was funded in the 13th Cornet Call (Collective Research Networking) by the German Federal Ministry for Economic Affairs and Energy (BMWi) and the German Federation of Industrial Research Associations (AiF).
(formerly Federal Ministry for Economic Affairs and Energy)
