In-process angle measurement and control for flexible sheet metal manufacture

A new method of controlling springback in small-radius pressbrake bending operations has been developed. This method provides a more accurate bending process, necessary for the further development of precision, small-lot sheet metal assembly manufacture. The pursuit of this research has led to the development of an inexpensive, high-resolution, on-line angle sensor. In addition, a simplified analytic model of the bending process was developed to predict springback in terms of material and tooling geometry variables. Finally, a springback control system has been developed with demonstrated accuracy of one-third of a degree in right-angle bends for cold-rolled steel samples covering a range of material properties.