Tooling-integrated sensing systems for stamping process monitoring

In-situ stamping process monitoring plays a critical role in enhancing productivity and ensuring part quality in sheet metal stamping. This paper investigates the realization of two sensing methods to create a tooling-integrated sensing system: mutual inductance-based displacement measurement for sheet draw-in, and distributed contact pressure measurement at the tool–workpiece interface. The two sensing systems are complementary in nature, and together, they significantly enhance the on-line observability of the stamping process. The performance of the draw-in sensor was evaluated using numerical simulations and experiments in a small-scale and a large-scale lab setup, and its effectiveness has been confirmed under the presence of wrinkled sheet. To study the spatial and temporal variations of the tool–workpiece contact pressure in a stamping operation, experiments were conducted on a customized panel stamping test-bed with an array of thin-film force sensors embedded below the die flange and die cavity. The force sensor data were then numerically interpolated to form the contact pressure distribution across the tool–workpiece interface, based on the thin plate spline (TPS) method. Comparison between the interpolated pressure obtained from the surface generation techniques and direct measurement using redundant sensors and a press mounted load cell confirms the validity of the new contact pressure sensing method. The integrated sensing technique provides insight into the stamping process by quantifying process variations and providing a reference base for process control to reduce product disparities. Additionally, new product and process designs can be created based on the quantified and referenced variations. Published by Elsevier Ltd.