SpringerLink
Log in

Environmental Temperature Considerations in Development of High-Precision Meso Deep Drawing Tool

  • Original Contribution
  • Published:
Journal of The Institution of Engineers (India): Series C Aims and scope Submit manuscript

Abstract

Design and manufacturing of the high-precision meso deep drawing tools, especially in the low mesoscale range, demands close tolerance and high positional accuracy. Variation in environmental temperature affects the dimensions of individual components and final assembly due to thermoelastic deformation. This paper describes an approach to estimate the thermal deformation and positional errors of the tool components using finite element simulation. A shift of 52.74 and 61.79 μm with reference to central plane is observed for the guide push holes on left-hand and right-hand sides, respectively, at 42 °C. The thermal deformation along X-direction is validated through a dedicated measurement system with an expanded uncertainty of 2.8594 µm m−1. Based on thermal error estimation, CNC program is reconstructed to compensate dimensionally during the manufacturing of relevant tool components. A dimensional chain analysis reveals a maximum offset of 18 μm between punch and die axes in the tool assembly. Using the developed meso deep drawing tool, cups of 5.5 mm diameter are deep drawn from 0.8-thick sheet of IS513 low-carbon steel. This paper discusses the thermal deformation modeling, development of software system and experimental results in detail. The increased positional accuracy with desired clearances enhances the quality of the drawn parts, thereby ensuring improvement in the tool performance and its life. The proposed approach can be applied in the development of micro-deep drawing and other forming tools.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. M. Geiger, M. Kleiner, R. Eckstein, N. Tiesler, U. Engel, Microforming. CIRP Ann. 50(2), 445–462 (2001)

    Article  Google Scholar 

  2. U. Engel, R. Eckstein, Microforming- from basic research to its realization. J. Mater. Process. Technol. 125–126, 35–44 (2002)

    Article  Google Scholar 

  3. F. Vollertsen, H.S. Niehoff, Z. Hu, State of the art in micro forming. Int. J. Mach. Tools Manuf. 46, 1172–1179 (2006)

    Article  Google Scholar 

  4. A.R. Razali, Y. Qin, A review on micro-manufacturing, micro-forming and their key Issues. Procedia Eng. 53, 665–672 (2013)

    Article  Google Scholar 

  5. S.B. Park, Y. Choi, B.M. Kim, J.C. Choi, A CAD/CAM system for deep drawing dies in a simple-action press. J. Mater. Process. Technol. 87(1–3), 258–265 (1999)

    Article  Google Scholar 

  6. Y. Qin, Forming-tool design innovation and intelligent tool-structure/system concepts. Int. J. Mach. Tools Manuf. 46, 1253–1260 (2006)

    Article  Google Scholar 

  7. L.C. Chan, M.W. Fu, N. Li, J. Lu, FEA-aided design of multi-stage drawing process and tooling for production of a miniature sheet metal component. Int. J. Adv. Manuf. Technol. 46(9), 993–1000 (2009)

    Article  Google Scholar 

  8. S. Salunkhe, S. Kumar, H.M.A. Hussein, An expert system for automatic design of compound dies, in AI Applications in Sheet Metal Forming. Topics in Mining, Metallurgy and Materials Engineering, ed. by S. Kumar, H. Hussein (Springer, Singapore, 2017)

    Google Scholar 

  9. Y. Qin, Integrated, multidisciplinary approaches for micro-manufacturing research, and new opportunities and challenges to micro-manufacturing. Proc IMechE Part N J. Nanomater. Nanoeng. Nanosyst. 232(1), 5–21 (2018)

    Google Scholar 

  10. Q.B. **, X.H. Dong, Study on micro deep drawing process and die design. Forging Stamp. Technol. 4, 57–61 (2007)

    Google Scholar 

  11. J. Bryan, International status of thermal error research. CIRP Ann. 50(2), 645–656 (1990)

    Article  Google Scholar 

  12. M. Weck, P. McKeown, R. Bonse, U. Herbst, Reduction and compensation of thermal errors in machine tools. CIRP Ann. 44(2), 589–598 (1995)

    Article  Google Scholar 

  13. J. Mayr, J. Jedrzejewski, E. Uhlmann, M.A. Donmez, W. Knapp, F. Härtig, K. Wendt, T. Moriwaki, P. Shore, R. Schmitt, C. Brecher, T. Würz, K. Wegener, Thermal issues in machine tools. CIRP Ann. Manuf. Technol. 61(2), 771–791 (2012)

    Article  Google Scholar 

  14. H. Schwenke, W. Knapp, H. Haitjema, A. Weckenmann, R. Schmitt, F. Delbressine, Geometric error measurement and compensation of machines—an update. CIRP Ann. Manuf. Technol. 57, 660–675 (2008)

    Article  Google Scholar 

  15. M. Sortino, S. Belfio, B. Motyl, G. Totis, Compensation of geometrical errors of CAM/CNC machined parts by means of 3D workpiece model adaptation. Comput. Aided Des. 48, 28–38 (2014)

    Article  Google Scholar 

  16. A. Oyanguren, J. Larrañaga, I. Ulacia, Thermo-mechanical modelling of ball screw preload force variation in different working conditions. Int. J. Adv. Manuf. Technol. 97(1–4), 723–739 (2018)

    Article  Google Scholar 

  17. A.M.A. Shahed, A.P. Longstaff, S. Fletcher, The application of ANFIS prediction models for thermal error compensation on CNC machine tools. Appl. Soft Comput. 27, 158–168 (2015)

    Article  Google Scholar 

  18. D. Zhao, Y. Bi, Y. Ke, An efficient error prediction and compensation method for coordinated five-axis machine tools under variable temperature. Int. J. Adv. Manuf. Technol. 96(9–12), 4431–4443 (2018)

    Article  Google Scholar 

  19. Doiron TD. https://emtoolbox.nist.gov/Temperature/Temperature%20and%20Dimensional%20Measurement.pdf. Accessed 16 Nov 2018

  20. IS 196-1966 (reaffirmed in 2001) Atmospheric Conditions for Testing. Indian Standards 1966

  21. G.T. Smith, Machine Tool Metrology (Springer, Cham, 2016)

    Book  Google Scholar 

  22. M.S. Shunmugam, New approach for evaluating form errors of engineering surfaces. Comput. Aided Des. 1, 368–374 (1987)

    Article  Google Scholar 

  23. M.S. Shunmugam, Assessment of errors in geometrical relationships. Wear 128, 179–188 (1987)

    Article  Google Scholar 

  24. N. Bosmans, J. Qian, D. Reynaerts, Design and Experimental Validation of an ultra-precision Abbe-compliant linear encoder-based position measurement system. Precis. Eng. 47, 197–211 (2017)

    Article  Google Scholar 

  25. ISO 230-3: 2007(E). Test code for machine tools - Part 3: Determination of thermal effects (reviewed & confirmed in 2014) International Organization for Standardization, 2007

  26. ISO 230-2. Test code for machine tools - Part 2: Determination of accuracy and repeatability of positioning numerically controlled axes. International Organization for Standardization, 2014

  27. JCGM 100. Guide to the expression of uncertainty in measurement (GUM) First edition, 2008

  28. MSA. Measurement Systems Analysis Manual, Fourth Edition, Automotive Industry Action Group (AIAG), Southfield, Michigan, USA, 2010

  29. Possolo A. Simple guide for evaluating and expressing the uncertainty of measurement results. NIST Technical Note 1900, 2015

Download references

Funding

This research did not receive any specific grant from funding agencies in the public, commercial or not-for-profit sectors.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, 600036, India

    D. Ramamoorthy & M. S. Shunmugam

Authors
  1. D. Ramamoorthy
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. M. S. Shunmugam
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. S. Shunmugam.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ramamoorthy, D., Shunmugam, M.S. Environmental Temperature Considerations in Development of High-Precision Meso Deep Drawing Tool. J. Inst. Eng. India Ser. C 101, 999–1014 (2020). https://doi.org/10.1007/s40032-020-00609-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40032-020-00609-z

Keywords

Search

Navigation