Seznam abstraktů 2026: POSTEROVÁ SEKCE B

This study investigates wall thickness variations during the multi-stage deep drawing of bearing housings under industrial-experimental conditions. The paper outlines a methodology for evaluating both material formability and wall thickness distribution within the drawn components. KOHAL 240 cold-rolled steel sheet (DC03 drawing quality), nominal thickness of 2mm served as the experimental material. To analyze material flow and thinning behavior, thickness was monitored across three drawing stages. Measurement accuracy was validated by comparing two distinct approaches: conventional manual measurement using a point-contact micrometer and advanced non-contact optical scanning via the GOM Scan 1 and Zeiss ScanPort systems. The resulting data, presented through comparative graphical analysis, demonstrate a high degree of correlation between the optical and manual methods. Observed deviations remained within acceptable experimental tolerances, confirming the reliability of non-contact scanning for monitoring complex forming processes.

This paper presents an analysis of the potential for automation of the hot die forging process, considering the types of forging units used and the feed and material handling strategies. The research is based on our own experience and R&D work related to the implementation, design, and testing of robotic cells for the production of die forgings, including high-volume production (≥0.5 million forgings per year). The paper focuses on comparing forging presses and hammers, taking into account the number of robots in the forging cell and the method of holding the semi-finished products - both through direct robotic gripping and by leaving the workpiece in the tool cells. The paper emphasizes the important role of FEM simulation software and robot trajectories in the design and optimization of robotic forging processes. The most typical cell configurations are presented, including two-robot systems used on presses and hammers. It has been demonstrated that forging presses favor the use of multi-robot systems (two robots per forging line) without holding the workpiece, which enables the simultaneous execution of several operations and increases automation efficiency. Hammer automation, on the other hand, requires limiting the number of robots (1-2) and adapting the gripping strategy to the dynamic nature of the process, which impacts the design of the cells and the sequence of operations. Effective automation of forging processes depends on the optimal selection of machine type, number of robots, and method of batch manipulation during the forging production process.

Based on the prior experience of IPB Polska Sp. z o.o. in Oświęcim, Poland, design specifications were formulated for the introduction of technological innovations in the production of vehicle door ring as a typical stamped-and-welded component.
The goal of these innovations was to produce the component as a single-piece, hot-stamped part made from laser-welded blanks (TWB) instead of the typical multi-piece cold-stamped and welded construction. These activities were planned to reduce the product’s weight, increase the structural strength of this component, and reduce the total number of manufacturing operations required to produce the finished component. A research and development project was secured to build a pilot production line for hot-forming and to verify the planned solution. This article presents the design phase of the innovative product and pilot plant, as well as the results of the practical verification of the designed solution under production conditions.
Acnowledgements: Project No. POIR.01.01.01-00-0813/17 entitled: “Research and development work on the technology for producing vehicle door ring in the form of a single-piece stamping obtained through the forming of a semi-finished product on a press” carried out between 2018 and 2023 at IPB Polska Sp. Z o. o. in Oświęcim, funded by the National Centre for Research and Development under the POIR programme.

Shear cutting operations, such as blanking, are critical in forming technology but often oversimplified in FE simulations, reducing predictive accuracy for cut edge quality. This study evaluates three failure modelling approaches for a FE model of DC04: the modified porous Gurson model and the Johnson-Cook model with element deletion and mesh separation. Experimental validation of the cutting characteristics rollover, burnish, fracture and burr showed that the JC model with mesh separation produced the most accurate results, with up to 99.86 % certainty. Based on this validated model, a factorial parameter study identified punch radius and sheet thickness as the dominant factors influencing burr height, while die radius and clearance exhibited minor effects. Numerical investigations of alternative blanking processes demonstrated that fine-blanking, counter-blanking and notch-blanking produced burr-free cuts, while hollow-blanking and two-stage blanking showed a less strong influence. These results confirm the capability of validated FE simulations for process optimisation.

The production of metallic sheet composites (layered, multi-material structures) by rolling is a manufacturing route that enables the integration of complementary material properties within a single product. This poster investigates the rollability of different composite architectures, with emphasis on how the layer arrangement, material pairing, rolling schedule (pass design), and process parameters influence final product quality. Special attention is paid to layer co-deformation and interfacial stability, as these factors largely define structural integrity and the viable processing window.
The methodology combines targeted experimental pass design with numerical modelling. The rolling schedule is defined in multiple steps, including the total and per-pass thickness reduction and the rolling mode (cold/hot, pre-rolling and subsequent rolling), aiming to achieve deformation with minimal relative displacement (slip) between layers. The modelling approach is used to evaluate stress-strain states, deformation compatibility of the layers, and interfacial loading conditions. Product quality is assessed using multiple criteria: layer thickness uniformity, dimensional accuracy and shape defects, surface integrity, and interface-related defects with a focus on bonding reliability.
The expected outcome is a practice-oriented overview showing which pass-design logic and parameter ranges lead to stable layer co-deformation for various metallic sheet composite structures, and which critical factors may trigger quality degradation or unreliable bonding. The presented framework supports rolling process design and quality prediction of layered sheet composites in both research and industrial applications.

The Cu-graphene composite combines the high electrical and thermal conductivity of copper with the extreme strength and stiffness of graphene. This composite is thus stronger, more wear-resistant and at the same time highly conductive. It is particularly suitable for new generation electrical conductors, thermal management in electronics, electrical contacts or commutators of electric motors. The addition of graphene significantly affects the plastic deformation of copper. The resulting deformation behavior is often a combination of strengthening and a change in the deformation mechanism. The presented study investigates the deformation behavior of this composite through the simulation of a uniaxial compression test using the finite element method in FORGE software using the Hensel-Spittel rheological model, compiled on the basis of a uniaxial compression test on the Gleeble device. The results indicate maximum flow stress values in the range from 250 MPa to 2130 MPa as the strain rate increases from 0.1 s−1 to 100 s−1. At higher strain rates, the effect of deformation heat plays a significant role, which locally leads to a significant softening of the investigated composite. This effect is all the stronger because at high strain rates the deformation process is practically adiabatic, when during deformation lasting less than a second there is not enough time for the heat generated to be dissipated. The maximum embedded strain then ranges from about 1.3 to 2.0.