Design of an Automated Sheet Metal Transfer System for Die Hardening
Niraula, Abinab (2016)
Niraula, Abinab
Hämeen ammattikorkeakoulu
2016
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-201603173282
https://urn.fi/URN:NBN:fi:amk-201603173282
Tiivistelmä
The purpose of this thesis was to design an automated facility that transfers a heated sheet metal specimen from the oven to a press hardening die, assembled in a hydraulic press. This project was commissioned by Sheet Metal Centre; a research and development department of HAMK University of Applied Sciences located in Hämeenlinna. A primary target of this thesis was to achieve a complete automated system, which would provide consistent specimen transfer time, leading to comparable test results for die hardening research.
Initially, a manual system was designed and a prototype was manufactured to be used in the transfer of hot sheet metal specimens, but inconsistencies were observed in the hardening results due to differences in the transfer time when using the manual transfer system. Hardening process is sensitive to the rate of cooling, which in turn, is related to the transfer time and this demanded an automated system to be designed. In developing the existing prototype, research was conducted to find an existing transfer system. Multiple automated systems were found for cold sheet metal transfer but none for hot sheet metals. This necessitated a completely new system design that could be used in elevated temperatures. A general approach to design was adopted to develop the manual prototype. This process involved multiple discussions with the customer and supervisor. Multiple ideas were generated and discussed with supervisor and the customer to validate the mechanism that performs each necessary mechanical actuation. Later these actuations were combined to form a complete system.
Multiple visits to the research site and meeting reviews played an important role in getting familiarised and understanding of the work. Implementing general design steps such as research, brainstorming, ideation, concept design and virtual prototype development resulted in two different transfer systems. One of the systems was selected by the customer for further development. The system designed will be manufactured and assembled at the Sheet Metal Centre to assist the die hardening research. The gripping tool for the system will be designed later in another project and any optimization or further development of the system, if needed, will be carried out then.
Initially, a manual system was designed and a prototype was manufactured to be used in the transfer of hot sheet metal specimens, but inconsistencies were observed in the hardening results due to differences in the transfer time when using the manual transfer system. Hardening process is sensitive to the rate of cooling, which in turn, is related to the transfer time and this demanded an automated system to be designed. In developing the existing prototype, research was conducted to find an existing transfer system. Multiple automated systems were found for cold sheet metal transfer but none for hot sheet metals. This necessitated a completely new system design that could be used in elevated temperatures. A general approach to design was adopted to develop the manual prototype. This process involved multiple discussions with the customer and supervisor. Multiple ideas were generated and discussed with supervisor and the customer to validate the mechanism that performs each necessary mechanical actuation. Later these actuations were combined to form a complete system.
Multiple visits to the research site and meeting reviews played an important role in getting familiarised and understanding of the work. Implementing general design steps such as research, brainstorming, ideation, concept design and virtual prototype development resulted in two different transfer systems. One of the systems was selected by the customer for further development. The system designed will be manufactured and assembled at the Sheet Metal Centre to assist the die hardening research. The gripping tool for the system will be designed later in another project and any optimization or further development of the system, if needed, will be carried out then.