The graph shows a range of factors involving the inner and outer sheet, the application pattern, the adhesive material, the nesting and hemming process and process steps in paint shop applications. Roll hemming operation can also be divided into several pre hemming and final hemming steps. At voestalpine polynorm, hemming is used as an assembly method for closures i. This article is devoted to the numerical simulation of the roller hemming of a curved piece, which has undergone prestrain equivalent to that of an opening part of an automobile after deep drawing. In hemming processes various product and process variants have to be considered. Like the first hemming process, in the second hemming process, the guide roller can move on the accurate path along the second groove 54 by the floating structure of the hemming roller 30 and the guide roller 32 thereby to perform the processing along the entire length of the flange 17.
Numerical analysis of high speed roller hemming processes. Analysis of roller hemming process for a vehicle tailgate. Other flexible roller hemming applications, which can include roller flanging, flat hem, rope hem, and jewelpinch hem. Cattopath algorithms on mathematical data, including arc support, for smooth and continuous robot motions. Roll hemming operation can also be divided into several prehemming and final hemming steps. In addition to conventional press hemming, the roller hemming process is used in the production of vehicle body parts based on economic and technological criteria. Virtually endless possibilities for system configurations that will ensure the leanest process to meet your. Hemming, deep drawing, fea, doe, roller, rollin, rollout, roll force, metal forming.
As the latest hemming process type, the roller hemming process uses industrial robots therefore. The indexing unit brings the hemming unit to the optimal angle before hitting the. Virtually endless possibilities for system configurations that will ensure the leanest process to meet your production needs. In this study, the roller hemming process of the tailgate of a vehicle has. These two rollers are used to carry out a threestep roller hemming process. This paper analyses roller hemming process, establish roller hemming system 3d models, include roller hemming tool system, roller hemming fixtures system and roller hemming robot. Research on the influence of the process parameters upon. Pdf a parametric investigation of roller hemming operation on a.
One is a flat roller and the other is a 30o taped roller. Rolleri vario can be mounted on any press brake model. Hemming presses are widely used in automotive manufacturing for hemming of sheetmetal body components. A device has been designed to hem these samples both by classical and rollhemming processes and to allow a comparison between both technologies.
Before the hemming operation, the auto body panels have to be flanged. A roller hemming system for edge hemming vehicle closures from nested metal panels includes an anvil robot moveably supporting a hemming anvil having a working surface, a clamping spider cooperable with the anvil robot for clamping the nested metal panels on the working surface, an anvil register including a base and a registration feature for matingly positioning the hemming anvil thereto, a. Its possible to download the document as pdf or print. First of all, the pressureviscosity effect in the model of parallelpanel squeeze is investigated, while the adhesive flow is.
Software performance for body in white, car body assembly. Too little fundamental process knowhow is available. Roll hemming the rollhemming process use one or more rollers, which are. Springback simulation of the process chain press line. Robotic roller hemming is increasingly popular against established hemming methods because of its flexibility, low cost investment and simply to use. Numerical simulation of the roller hemming process based on. Numerical simulation of the roller hemming process based. It is the process of bendingfolding the flange of the outer panel over the inner one. A device has been designed to hem these samples both by classical and roll hemming processes and to allow a comparison between both technologies. Numerical analysis of the roller hemming process deepdyve. Springback simulation of the process chain press line forming. For example, the minimum flange height obtained by mechanical flanging is typically greater than 4 mm.
A robot roller hemming process of a tailgate of saab 93 sportcombi model is investigated as a case study in this. By applying task separation, robot coordination, and robot cell configuration principles in. To achieve a perfect process result in roller hemming with robots, offlineprograming and optimization are essential. Request pdf numerical analysis of the roller hemming process numerical simulation of the roller hemming process is studied in this approach. Roll hemming operation can also be divided into several prehemming and final hemming process steps. Tools are set up for flanging, prehemming, and final hemming. Hemming is a technology used in the automotive industry to join inner and outer closure panels together hoods, doors, tailgates, etc. The threedimensional simulations of the hemming of an automotive hood was elaborated. Versatility of hemming conditions in traditional closure panels, as well as other components such as rear wheelhouse openings, roofssunroofs, and bonnets. In several processing steps, the roller hemming head bends the flange of the external shell over the inner, or reinforcing, sheet.
The influences on rollin from adhesives, anisotropy. Tools are set up for flanging, pre hemming, and final hemming. This paper focused on the robot roller hemming process and how to reduce its cycle time by introducing a fast roller hemming process. This roller hemming head consists of a body, some guides and a number of rolls that are designed according to the geometry of the part in each case. Flanging and hemming of auto body panels using the electro. Research on the influence of the process parameters upon the. Have a look at the manual relion bp200 hem 741crel 3 manual online for free.
Jan 29, 2016 fastsuite edition 2 provides advanced robot offline programming for virtually any production technology. Roller hemming in prototype construction the use of roller hemming to process multilayer sheet metal, e. The roller hemming device was designed and built based on a conventional roller hemming device with an additional capability of attaching the laser beam delivery optics. Springback simulation of the process chain press line forming and roller hemming processes p.
A parametric investigation of roller hemming operation on a curved edge part article pdf available in archives of civil and mechanical engineering 191. Adaptable technology another advocate for the technology is alan stapelberg, biw product manager for robot roller hemming supplier and system integrator abb engineering in shanghai. Introduction roller hemming is a method used in the automotive industry to join two preformed metal panels. Numerical analysis of the roller hemming process springerlink. Us20090038361a1 flying roller hemming anvil process. Aug 07, 2008 like the first hemming process, in the second hemming process, the guide roller can move on the accurate path along the second groove 54 by the floating structure of the hemming roller 30 and the guide roller 32 thereby to perform the processing along the entire length of the flange 17. Using the em bending process, this flange height can be reduced. In roller hemming, as the name suggests a robot runs a roller around the edge of the sheet so that hemming takes place as a continuous, sequential and in localized operation. It is in principle a more simple and economic system than tabletop hemming, offering a higher degree of flexibility.
Prehemming,final hemming and corner hemming can be performed in a single station to save on space and investment. Sulfur and lead allow for high speeds and feeds in machining, but the thread finish can suffer. Simulation of roller hemming process to correlate the. A 2d simulation model is developed in chapter 5 which can simulate the. Comau roller hemming solutions for flexible vehicle manufacturing. In recent years the process simulation of entire manufacturing chains in sheet metal forming has gained more ground on its way to be established in the validation of feasibility and the meeting of quality targets. Dec 25, 2011 numerical simulation of the roller hemming process is studied in this approach. Simulation of roller hemming process to correlate the design. With fastsuite, roller hemming can be supported with the following features. Roller hemming a particularly flexible solution to the manufacture of addon parts.
The accuracy of the operation significantly affects the appearance of the cars outer surfaces and is therefore a critical factor in the final quality of a finished vehicle. A study on sheet metal hemming process sciencedirect. Hemming and seaming are two similar metalworking processes in which a sheet metal edge is rolled over onto itself. Rollinout results are obtained through a simulation and an experiment to verify the accuracy of the numerical model. Combined hardening is used for steel panel bsufd roller hemming. Influence of prestrain on the numerical simulation of the. Roll hemming operation can also be divided into several pre hemming and final hemming process steps. Hemming is the process in which the edge is rolled flush to itself, while a seam joins the edges of two materials. The process allows the advantage of using the robot controlled hemming head to hem several different components in a. Choosing hirotec america as your robotic roller hemming specialist will provide. Therefore, the metamodel requires a formulation which allows an easy adjustment of these.
No limitation on part shape, changeable roller hemming heads and system to accommodate to different parts. This article researched the influence of tcprtp distance on the accuracy of product in robot roller hemming through orthogonal experiments used as guidance to optimize the parameter of tcprtp distance in practice. Roller hemming solutions for flexible vehicle manufacturing. To enable an effective evaluation process, a hemmingspecific and elementbased metamodel approach will now be presented. Nowadays, especially the simulation of manufacturing automotive sheet metal components such as doors, hoods roofs etc. Influence factors the quality of the final hem flange is influenced by many different factors.
Hemming is a sheet metal joining process which is widely used for vehicle closures. The process uses traditional hydraulically operated stamping presses to hem closure parts and being the last forming process in stamping, it determines the external quality of automotive outer parts such as doors, hood and trunklid. Parametric optimization of linear rollhemming process for metal sheets. Fastsuite edition 2 provides advanced robot offline programming for virtually any production technology. Fastsuite helps you to achieve a perfect process result in roller hemming with robots. Recently, roller hemming process has been introduced for hemming of aluminum automotive closing parts such as doors, roofs and hoods.
Meshes are produced based on the deformation state of the panel. The roller hemming technology is valid both for parts made in steel and aluminum. Numerical simulation of the roller hemming process is studied in this approach. In this paper, the hemming adhesive is taken as a viscous newtonian fluid. The technique not only enhances the overall strength of the join but is also aesthetically pleasing.
The numerical modeling of the process is developed in a finiteelement code and the results obtained for this particular geometry are then presented. Robot or roller hemming constitutes a particularly flexible solution to the production of addon parts. Sheet metal hemming process can be generally classified into two major categories such as classical conventional hemming and roller hemming process. Introduction roller hemming is a method used in the automotive industry to. A robot roller hemming process of a tailgate of saab 93 sportcombi model is investigated as a case study in this paper. Laser assisted roller hemming of nonductile material for. The roller hemming system could be verified before it is put into operation by virtual manufacturing technology. Design and analysis of aframe for roller hemming cell. Request pdf analysis of roller hemming process for a vehicle tailgate closure hemming is a sheet metal joining process which is widely used for vehicle closures. Development of an empirical model to determine results from. Robotic roller hemming system features of roller hemming flexibility no limitation on the flange angles, rollers can adjust up to.
It can be adapted to any machine table thanks to mm units. Pdf this study presents the roller hemming operation of a curved edge sheet metal which is critical in terms of dimensional accuracy and deformation find. Hems are commonly used to reinforce an edge, hide burrs and rough edges, and improve appearance. Comau roller hemming solutions for flexible vehicle. Pdf introducing fast robot roller hemming process in. An industrial robot guides the hemming roller and forms the flange. Robotic roller hemming can be used to replace some flanging operation reducing overall investment costs. Simulation of the robot roller hemming process university of. Rollhemming is used for the manufacture of low to medium production volumes. Robot roller hemming is a relatively new process, so. Numerical analysis of the roller hemming process request pdf. Development of an empirical model to determine results.
Simulation of the robot roller hemming process university. The flange of the outer panel is bent over the inner panel in progressive steps by means of the roller hemming head. Introducing fast robot roller hemming process in automotive. An innovative process was developed at our research center to incorporate a laser beam at the hemming roller to introduce a localized heating source. Ingemat assembly lines with roller hemming closures vs20 mercedes benz espana 2012 duration. A double roller tool and a robot guidance system from ai are put into effect. Mechanical joining techniques technologies and process.
A robot guides the hemming roller and forms the flange. The correlations between the hemming parameters such as flange length, roller radius, prestrain, rolling direction, pre hemming robot path on hem surface, are. The hoq hemming head enables controlled robotic hemming with hemming indicator. With our robotic roller hemming solutions it is possible to process different components and achieve optimal capacity utilization. Pdf parametric optimization of linear rollhemming process for. The actual mechanical hemming process carries some limitations when dealing with aluminum. In the roller hemming process, the highviscosity adhesive has affected the forming process of metal sheets, especially lightweight materials. Oct 15, 2014 roller hemming solutions for flexible vehicle manufacturing. Laser assisted roller hemming of nonductile material for automotive. Two hemming processes are generally used to manufacture vehicle body parts. Hemming is a process by which a metal sheet edge of an outer part is bent around an inner part.
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