On the use of Process Work as an Indicator for Process Disturbance in industrial Sheet Metal Forming

This study explores the estimation of process work in the sheet metal forming process by numerically integrating the punch force curve as a function of the press crank angle. Two numerical integration methods, the trapezoidal rule and Simpson’s 3/8 rule, are evaluated for their ability to estimate process work. While both methods yielded similar results, the Simpson 3/8 rule was found to produce significantly lower estimation errors. The method was then tested in an industrial case study involving the production of Volvo XC90 front door inner components. By analyzing the process work for each blank, it was found that the method effectively captured changes in applied cushion force and material coil. A further analysis, incorporating average lubrication data, showed that the process work also accurately reflected variations in lubrication conditions. The results suggest that process work could serve as a cost-effective and efficient tool for in-line monitoring of process health and has the potential to improve process monitoring and quality control in industrial sheet metal forming operations.