Improved part quality in stamping using Multi-Input Multi-Output (MIMO) process control

The binder force in sheet metal forming controls the material flow into the die cavity, and maintaining precise material flow characteristics is crucial for producing a high-quality stamped part. Process control can be used to adjust the binder force based on tracking a reference punch force trajectory to improve part quality and consistency. The purpose of this paper is to present a systematic approach to the design and implementation of a suitable MIMO process controller. The approach includes modeling of the sheet metal forming process, and the design of the process controller based on simulation. Experimental results from a complex-geometry part show that the MIMO process controller, designed through simulation, is effective.