Benny Endelt | Aalborg University (original) (raw)

Papers by Benny Endelt

Composites Part B: Engineering

IOP conference series, Nov 25, 2019

Over the last two decades there has been and increasing academic and industrial focus on process ... more Over the last two decades there has been and increasing academic and industrial focus on process robustness and process control applied on sheet-metal forming processes and a high number of control schemes has been proposed. However, many of proposed control schemes rely on process data sampled during the punch stroke (in case of stamping and deep drawing) e.g. draw-ill sensors and the absent of robust sampling technologies is on of the main barriers preventing industrial implementation. One approach to avoid in-process sampling is to apply an part-to-part control strategy, where the process parameters are updated based on post-processing samples e.g. flange geometry. Different algorithms has been proposed, the current article will adapt the algorithm proposed by Endelt (2017) which are based on a Gauss-Newton formulation (non-linear least-square). The control scheme is applied on the NumiSlieet'08 S-rail benchmark, the algorithm has previously been applied on a square deep-drawing with good results and the present paper illustrate the flexibility of the proposed part-to-part control scheme, as the algorithm can be directly adopted to s-rail process using the design rule from the original paper.

The data describes the measurement of a v-bend shape formed during multi-scan laser forming. The ... more The data describes the measurement of a v-bend shape formed during multi-scan laser forming. The purpose of the measurements was to determine the dynamic response during laser forming of a v-bend. A measurement scanner was used to measure the height of a line perpendicular to the heating scan line of a laser during laser forming. In order to estimate a surface, 105 samples were made with identical settings with the measurement scanner moved along the heating scan line between samples. A total of 21 positions along the heating scan line were measured. Each position was measured using 5 samples. Due to a memory problem, the measurement scanner could only measure about 3.12 seconds at a time. The measurement scanner is started slightly before each heating scan line starts. Furthermore, each heating scan line is split into its own text file in the data set. This data set contains 21 folders, one for each position of the measurement scanner along the heating scan line. The folders are named as 'ymm', where y is the distance from the trailing edge of the heating scan line, '_' is used instead of decimals here. Each folder contains 30 text files, 6 for each of the samples used, structured as (x, y, z, t). Each file is named as 'sample_i_plate_j_scannumber_k.txt', where i is the sample number (1-5) at this position, j is the plate number (1 or 2), k is the scan number (1-6). Scan number 6 does not contain any heating, but is set as a final measurement of about 60 seconds after forming. Warning: The unzipped data fill 51.6 GB

Journal of Physics: Conference Series, Sep 1, 2017

Materials today communications, Sep 1, 2021

In case of severe accidents like loss of coolant accident with failure of emergency core cooling ... more In case of severe accidents like loss of coolant accident with failure of emergency core cooling system, the pressure tubes get heated quickly causing severe deformation. In this paper, an analytical solution technique has been used for calculating the radial deformation behaviour of pressure tubes. The analysis is carried out for different cases when the pressure tube is subjected to different values of internal pressure and heating rates. In the absence of specimen level creep test data of Indian pressure tube, data of Canadian pressure tube of similar material has been used. Due to observed differences between experimental and analytical values of radial deformation with time, the actual parameters have been calibrated from component level experiments using an optimization algorithm. Both uniaxial and bi-axial states of stress have been considered. Finite element method has also been used to calculate radial deformation of pressure tube and compared with experiment.

International Journal of Material Forming, Aug 1, 2009

A new tool design concept for deep drawing is presented. The design features a hydraulic shimming... more A new tool design concept for deep drawing is presented. The design features a hydraulic shimming system providing a variable blank holder force (BHF). An objective function describing the geometric quality of the drawn part and the process stability is formulated. The objective function is used in a gradient based optimization scheme to find a set of optimal loads for

Journal of Materials Processing Technology, 2013

ABSTRACT The performance of a feedback control system is often limited by the quality of the mode... more ABSTRACT The performance of a feedback control system is often limited by the quality of the model on which it is based, and often the controller design is based on trial and error due to insufficient modeling capabilities. A framework is proposed where the controller design is based on classical state space control theory and time series. The system plant has been modeled using non-linear finite element and the gain factors for the control loop were identified by solving the optimal control problem using a non-linear least square optimization algorithm.The proposed design method has been applied on a deep drawing operation where the objective was to control material flow throughout the part using only spatial information regarding flange draw-in. The control system controls both the magnitude and distribution of the blank-holder force.The methodology proved stable and flexible with respect to controlling the dynamic behavior of the system and the numerical tests showed that it is possible to control the material flow.Preliminary experimental results show that the proposed control system can eliminate process instability when the process is subject to a systematic error.

arXiv (Cornell University), Jul 7, 2023

This paper investigates a common rail cylinder lubrication system for large two-stroke marine die... more This paper investigates a common rail cylinder lubrication system for large two-stroke marine diesel engines using electronically controlled injectors. The system is studied using the Bosch rate of injection measurement technique The common rail injector has a buildup of mass flow of approximately 1 ms as the injector opens until the nozzle is choked from cavitation. Using a highly viscous fluid, the Bosch rate of injection method is able to predict the injected amount with an error of 5% or lower for nearly the entire tested delivery range of 2 mg to 21 mg. Lubrication of cylinder liners and piston rings is a crucial parameter in operating a two-stoke marine diesel engine efficiently. Both over and under lubrication is harmful for the engine, so the ability to accurately dose the cylinder oil is very important. A mass flow build up time of 1 ms promises high accuracy of dosage even down to 2.5 mg per injection. This paves the way for injecting the oil where and when it is needed, which in turn will improve engine performance and lower harmful emissions.

... Benny Endelt∗ and Karl Brian Nielsen∗∗ The Sheet Metal Forming Group Department of Production... more ... Benny Endelt∗ and Karl Brian Nielsen∗∗ The Sheet Metal Forming Group Department of Production, Aalborg University, Denmark ∗e-mail: endelt ... a, h, p and M. Further, a similar relation exists between the equivalent stress and the exponential hardening law, described by the ...

A user dened material with shear rate and, optionally, temperature dependent viscosity was implem... more A user dened material with shear rate and, optionally, temperature dependent viscosity was implemented and validated in reference [1] from 6th European LS-DYNA Users' Conference, copyright c by Engineering Research AB (ERAB AB). Shear rate dependence was expressed with a Yasuda function and temperature dependence with an Arrhenius function. This document describes the keyword data blocks and the FORTRAN code for the user material model.

Composites Part B: Engineering

IOP conference series, Nov 25, 2019

Over the last two decades there has been and increasing academic and industrial focus on process ... more Over the last two decades there has been and increasing academic and industrial focus on process robustness and process control applied on sheet-metal forming processes and a high number of control schemes has been proposed. However, many of proposed control schemes rely on process data sampled during the punch stroke (in case of stamping and deep drawing) e.g. draw-ill sensors and the absent of robust sampling technologies is on of the main barriers preventing industrial implementation. One approach to avoid in-process sampling is to apply an part-to-part control strategy, where the process parameters are updated based on post-processing samples e.g. flange geometry. Different algorithms has been proposed, the current article will adapt the algorithm proposed by Endelt (2017) which are based on a Gauss-Newton formulation (non-linear least-square). The control scheme is applied on the NumiSlieet'08 S-rail benchmark, the algorithm has previously been applied on a square deep-drawing with good results and the present paper illustrate the flexibility of the proposed part-to-part control scheme, as the algorithm can be directly adopted to s-rail process using the design rule from the original paper.

The data describes the measurement of a v-bend shape formed during multi-scan laser forming. The ... more The data describes the measurement of a v-bend shape formed during multi-scan laser forming. The purpose of the measurements was to determine the dynamic response during laser forming of a v-bend. A measurement scanner was used to measure the height of a line perpendicular to the heating scan line of a laser during laser forming. In order to estimate a surface, 105 samples were made with identical settings with the measurement scanner moved along the heating scan line between samples. A total of 21 positions along the heating scan line were measured. Each position was measured using 5 samples. Due to a memory problem, the measurement scanner could only measure about 3.12 seconds at a time. The measurement scanner is started slightly before each heating scan line starts. Furthermore, each heating scan line is split into its own text file in the data set. This data set contains 21 folders, one for each position of the measurement scanner along the heating scan line. The folders are named as 'ymm', where y is the distance from the trailing edge of the heating scan line, '_' is used instead of decimals here. Each folder contains 30 text files, 6 for each of the samples used, structured as (x, y, z, t). Each file is named as 'sample_i_plate_j_scannumber_k.txt', where i is the sample number (1-5) at this position, j is the plate number (1 or 2), k is the scan number (1-6). Scan number 6 does not contain any heating, but is set as a final measurement of about 60 seconds after forming. Warning: The unzipped data fill 51.6 GB

Journal of Physics: Conference Series, Sep 1, 2017

Materials today communications, Sep 1, 2021

In case of severe accidents like loss of coolant accident with failure of emergency core cooling ... more In case of severe accidents like loss of coolant accident with failure of emergency core cooling system, the pressure tubes get heated quickly causing severe deformation. In this paper, an analytical solution technique has been used for calculating the radial deformation behaviour of pressure tubes. The analysis is carried out for different cases when the pressure tube is subjected to different values of internal pressure and heating rates. In the absence of specimen level creep test data of Indian pressure tube, data of Canadian pressure tube of similar material has been used. Due to observed differences between experimental and analytical values of radial deformation with time, the actual parameters have been calibrated from component level experiments using an optimization algorithm. Both uniaxial and bi-axial states of stress have been considered. Finite element method has also been used to calculate radial deformation of pressure tube and compared with experiment.

International Journal of Material Forming, Aug 1, 2009

A new tool design concept for deep drawing is presented. The design features a hydraulic shimming... more A new tool design concept for deep drawing is presented. The design features a hydraulic shimming system providing a variable blank holder force (BHF). An objective function describing the geometric quality of the drawn part and the process stability is formulated. The objective function is used in a gradient based optimization scheme to find a set of optimal loads for

Journal of Materials Processing Technology, 2013

ABSTRACT The performance of a feedback control system is often limited by the quality of the mode... more ABSTRACT The performance of a feedback control system is often limited by the quality of the model on which it is based, and often the controller design is based on trial and error due to insufficient modeling capabilities. A framework is proposed where the controller design is based on classical state space control theory and time series. The system plant has been modeled using non-linear finite element and the gain factors for the control loop were identified by solving the optimal control problem using a non-linear least square optimization algorithm.The proposed design method has been applied on a deep drawing operation where the objective was to control material flow throughout the part using only spatial information regarding flange draw-in. The control system controls both the magnitude and distribution of the blank-holder force.The methodology proved stable and flexible with respect to controlling the dynamic behavior of the system and the numerical tests showed that it is possible to control the material flow.Preliminary experimental results show that the proposed control system can eliminate process instability when the process is subject to a systematic error.

arXiv (Cornell University), Jul 7, 2023

This paper investigates a common rail cylinder lubrication system for large two-stroke marine die... more This paper investigates a common rail cylinder lubrication system for large two-stroke marine diesel engines using electronically controlled injectors. The system is studied using the Bosch rate of injection measurement technique The common rail injector has a buildup of mass flow of approximately 1 ms as the injector opens until the nozzle is choked from cavitation. Using a highly viscous fluid, the Bosch rate of injection method is able to predict the injected amount with an error of 5% or lower for nearly the entire tested delivery range of 2 mg to 21 mg. Lubrication of cylinder liners and piston rings is a crucial parameter in operating a two-stoke marine diesel engine efficiently. Both over and under lubrication is harmful for the engine, so the ability to accurately dose the cylinder oil is very important. A mass flow build up time of 1 ms promises high accuracy of dosage even down to 2.5 mg per injection. This paves the way for injecting the oil where and when it is needed, which in turn will improve engine performance and lower harmful emissions.

... Benny Endelt∗ and Karl Brian Nielsen∗∗ The Sheet Metal Forming Group Department of Production... more ... Benny Endelt∗ and Karl Brian Nielsen∗∗ The Sheet Metal Forming Group Department of Production, Aalborg University, Denmark ∗e-mail: endelt ... a, h, p and M. Further, a similar relation exists between the equivalent stress and the exponential hardening law, described by the ...

A user dened material with shear rate and, optionally, temperature dependent viscosity was implem... more A user dened material with shear rate and, optionally, temperature dependent viscosity was implemented and validated in reference [1] from 6th European LS-DYNA Users' Conference, copyright c by Engineering Research AB (ERAB AB). Shear rate dependence was expressed with a Yasuda function and temperature dependence with an Arrhenius function. This document describes the keyword data blocks and the FORTRAN code for the user material model.