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Development of Burr-free Meso Punching System

Development of Burr-free Meso Punching System. Byeong Hee Kim Division of Mechanical Engineering and Mechatronics, Kangwon National University. Contents. Objectives Burr formation mechanism Meso punching system Auto-aligning algorithms Experimental results and discussion Conclusion.

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Development of Burr-free Meso Punching System

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  1. Development of Burr-free Meso Punching System Byeong Hee Kim Division of Mechanical Engineering and Mechatronics, Kangwon National University pmlab.kangwon.ac.kr

  2. Contents • Objectives • Burr formation mechanism • Meso punching system • Auto-aligning algorithms • Experimental results and discussion • Conclusion pmlab.kangwon.ac.kr

  3. Monitoring system Punching system Controller Meso Deburring M/C Objectives Meso Punching System Punching system + Deburring M/C Modules of Desktop factory pmlab.kangwon.ac.kr

  4. Rollover Burnish zone Fracture zone 2nd burnish zone Burr Depth of the crack penetration Mechanism of burr formation • The crack initiates from the top initial indent point (A) and connects to the bottom initial indent point (B). pmlab.kangwon.ac.kr

  5. Troubles caused by burrs • Reduce the quality of machined (sheared) parts • Cause interference, jamming and misalignment during assembly procedures • Safety hazard to personnel • Hard to predict • Hard to avoid • De-burring is time-consuming and costly pmlab.kangwon.ac.kr

  6. insulatedpunch-die interface laser aligner pneumatic punching head sheet metal feeding system micro aligning stage Meso -punching machine pmlab.kangwon.ac.kr

  7. System operation pmlab.kangwon.ac.kr

  8. Initial punch-die alignment procedure Steps • X-Y table moves toward -X until the punch contacts the die. • Table goes backward to the opposite direction before the new contact signal is detected. • Distance between the contact points can be calculated by using electric pulse signals. • Table moves to the center of both points. pmlab.kangwon.ac.kr

  9. Initial alignment example pmlab.kangwon.ac.kr

  10. Principle of in-situ alignment • Step 1 Sheet metal is fed to the designated position by the feeding actuator. • Step 2 Burr heights at the position ① and ② are measured by the laser probe. • Step 3 Difference between burrs heights is calculated • Step 4 Table is moved to the right or the left minutely according to the value of the difference. pmlab.kangwon.ac.kr

  11. Spot size is reduced to1~2㎛ Spot size reduction • Introducing achromatic doublet lens • Burr height pmlab.kangwon.ac.kr

  12. Experimental Conditions pmlab.kangwon.ac.kr

  13. Effect of initial alignment Brass t = 0.05 mm c = 10 mm 3 × 3 mm square hole Aluminum t = 0.2 mm c = 10 mm Misaligned Aligned pmlab.kangwon.ac.kr

  14. Burr height w.r.t. clearance pmlab.kangwon.ac.kr

  15. 30mm 6mm Effect of in-situ alignment (copper) Misaligned t = 50 mm c = 10 mm Aligned t = 50 mm c = 10 mm SEM photo Laser output pmlab.kangwon.ac.kr

  16. Ultrasonic deburring conventional method reversal flow resistance method Deburring machine Before deburring After deburring pmlab.kangwon.ac.kr

  17. Conclusion • We developed the precision meso-punching system and introduced two kinds of punch-die auto aligning methods : the punch-die contact sensing method and the in-situ self-aligning method • By reducing the spot size of the laser under 2 micrometers by the achromatic lens system, we can get the more accurate dimensional information of the burr • The burrs formed during the punching process can be uniformized and minimized by using aligning methods. • Novel deburring method was developed for almost burr-free parts. pmlab.kangwon.ac.kr

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