Soft sensor-based inline geometry control of hole-rolled polygon hubs

New machine concepts, such as the 3D Servo Press, make it possible to implement and study new forming processes like the flexible hole-rolling. In combination with the ongoing development of models, new control concepts can be developed and thus increase productivity of manufacturing systems. As part of this work, a soft sensor was developed to predict the part geometry of a polygon profile during the process of hole rolling based on the process forces and the ram position. This prediction was used in an experimental investigation to set up an inline geometry control to compensate for the geometric error due to roller deflection during the process.