Adaptive process control strategy based on accurate modeling of a two-step micro bending process: EHT 23259

viiAbstractThe aim of the thesis is the development of accurate numerical models to allow for a virtual tryout of the process behavior, the mappingof the behavior with metamodels, the application of these modelsfor controland the demonstrationofthe control strategyon adaptive processes. The investigated process is a two-step bending process, with an over bending and a subsequent reversed back bending.For an accurate description of the bending process, the focus is set on thematerial description. Aversion of the recently developed HAH modelis used for this purpose.Different hardening models have been com-pared and applied on the two-step bending process and the validation test. Finally, the validation of the bending shows in general a good agreementin the prediction of the bentangle. Sensitivity studies are conductedto investigate the influence of the chosen measured values and control parameteron the quality parameter to be able to evaluate if the process is controllable.Knowing the process behavior, two control algorithmshave been worked out. The models for the controller are based on simulation data or on measured data.The stability of the two approaches hasbeen evaluated and the influence of noise on the measurement is determined by simulat-ing different scenarios. Theapproaches have been implemented and demonstratedto improve the quality of the produced parts. Finally, the resultson the demonstration line show that especially for longer term runs the quality of the parts can be improved by using process control. The target value is reached for all tests.