Zero Failure Production Methods Based on a Process Integrated Virtual Control

Although the virtual methods are nowadays fully established as a widely used tool in the planning and optimization of forming processes they are still completely omitted for a direct, intelligent process control in the later production of the parts. The paper presents a proposal for a Process-Integrated-Virtual-Control (PIVC) considering the real process perturbations induced by deviations of material properties as well as by further time dependent process parameters like the tool temperature. For the detection of the material deviations an in-line eddy-current measurement method and the appropriate evaluation method for the definition of the stochastic yield curves will be presented. The paper closes with a virtually taught control system modifying the blank-holder forces in dependency of thermal conditions and material deviations. The goal of this PIVC coupled to in-line process controls is to achieve a Zero Failure production even under alternative time dependent process conditions