This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Monitoring and Control of Equipment and Process in Cold Extrusion
Annotation ability available
Sector:
Language:
English
Abstract
Cold extrusion and forging processes are complex. They require monitoring and controlling the appropriate parameters to ensure high productivity and continued competitiveness of North American press and manufacturing companies. Current average productivity rates in high-volume, high-tonnage operations are often less than 60 percent, and the lost production capacity is mainly due to equipment failures and unreliable process control. The results presented in this paper pertain to identifying root causes for lost production in an automated facility running multiple high tonnage capacity presses and the tools developed to monitor and control the key parameters to improve productivity and eliminate downtime due to catastrophic equipment failure. To gain insight into various equipment and process related phenomena that lower productivity, a spectrum of sensors was installed inside of the dies and on mechanical components of two identical presses in the facility. A system comprising multiple computers and high volume magneto-optical storage archives and analyzes signals from these sensors to monitor the load on various components of the presses, process parameters and tonnage signatures. This system is also able to set control limits on a real-time basis. Detailed information pertaining to sensor placement and data analysis algorithms is presented in the paper. Example results that indicate the feasibility of predictive process control and monitoring as a promising solution for maximizing process efficiency and product quality are also included.
Recommended Content
Authors
Topic
Citation
Barnett, K., Duggirala, R., Hitz, D., and Spiewak, S., "Monitoring and Control of Equipment and Process in Cold Extrusion," SAE Technical Paper 981340, 1998, https://doi.org/10.4271/981340.Also In
References
- Altan, T. Oh S.I. Gegel, H.L. 1983 “Metal Forming: Fundamentals and Applications” ASM Metals Park, OH
- Spiewak, S.A. 1994 “Automated Supervision of Machine Tools” “Automated Supervision in Manufacturing” Szafarczyk, M. Springer
- Carlson, J. 1991 “Model Based Predictive Monitoring and Diagnosis for Rotating Machinery” University of Wisconsin-Madison
- Padmanabhan, V. Duggirala, R. Hitz, D. 1994 Intelligent Cold Extrusion (ICE) Project - Task 1 Report: Extrusion Press Characterization NCMS
- Padmanabhan, V. Duggirala, R. Bartley, T. Hitz, D. 1994 Intelligent Cold Extrusion (ICE) Project - Task 2 Report: Extrusion Press Failures NCMS
- NCMS ICE Database NCMS
- Spiewak, S.A. 1990 “The Enhancement of Monitoring and Failure Prediction Capabilities of the MMMS System” General Motors Technical Center
- PM 2000 Production Monitoring Bresson Rupp Lipa & Co. Ann Arbor MI
- Spiewak, S.A. 1991 “A Predictive Monitoring and Diagnosis System for Manufacturing” Annals of the CIRP 40 1 401 404
- Spiewak, S.A. 1995 “Emerging Trends in Automatic Supervision of Machine Tools” Int'l Conf. on Monitoring and Automatic Supervision Warsaw Poland 1995 49 60
- DeVries M.F. Duffie N.A. Lorenz R.D. Sanders J.L. Spiewak, S.A. 1994 “Laboratory for Applied Manufacturing Controls” Proc. of the 1994 NSF Design and Manufacturing Grantees Conference MIT Boston MA 537 8
- Spiewak S.A. Di Corpo, J. 1991 “Adaptive Compensation of Dynamic Characteristics for in-Process Sensors” ASME Jnl. of Engineering for Industry 113 198 206
- Spiewak, S. A. 1992 “Adaptive Compensation of In-Process Sensors” Proc. NSF Design and Manufacturing Systems Conference Atlanta, GA 1093 1097
- Spiewak, S.A. 1989 “Data Base for the Results of Monitoring and Diagnosis of Machine Tools” General Motors Technical Center
- Duggirala, R. Spiewak, S.A. 1997 “In-die Ejection Force Measurement in Forming Operations”