Computer Methods in Materials Science
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ISSN 2720-4081
e-ISSN: 2720-3948
Issue Date
2025
Volume
Vol. 25
Number
No. 2
Description
Journal Volume
Computer Methods in Materials Science
Vol. 25 (2025)
Projects
Pages
Articles
Design and implementation of a digital infrastructure for autonomous open-die forging
(Wydawnictwa AGH, 2025) Rechenberg, Roy; Korpala, Grzegorz; Jabłońska, Magdalena; Wojtaszek, Marek; Zyguła, Krystian; Tkocz, Marek; Bednarczyk, Iwona; Kowalczyk, Karolina; Prahl, Ulrich
Open-die forging is a key process for manufacturing large components such as generator shafts and crankshafts for ship engines. Despite its industrial relevance, the process remains dependent on manual labour and operator expertise, leading to challenges in process stability, reproducibility, and efficiency. Traditional automation approaches are impractical due to the high variability and low production volumes typical of open-die forging. At the Institute of Metal Forming (IMF) at the TU Bergakademie Freiberg, a novel concept for autonomous open-die forging has been developed and tested. The system combines conventional forging equipment with advanced technologies, including industrial robotics, 3D laser scanning, thermal imaging, and modular control software. Central to the concept is a robot cell operating as a distributed system, where sensor data is used to create a digital twin of the workpiece. This enables adaptive process planning and real-time autonomous operative adjustments. A process planning tool generates pass sequences and commands for manipulator movements, while an electromechanical interface allows indirect control of the forging press. The modular software architecture, coordinated by a central core-module, ensures flexibility and facilitates integration into different production environments. Initial trials demonstrate the system’s potential to improve process stability and quality while reducing dependency on manual operation. Ongoing work focuses on refining the concept to meet industrial requirements and support advanced material applications.
Evaluation of deformation inhomogeneity in multi-layered steel-titanium and steel-magnesium systems
(Wydawnictwa AGH, 2025) Pabich, Bartłomiej; Żurowski, Bartłomiej; Kwiecień, Marcin; Majta, Janusz
In the presented study, plastometric tests using channel die compression were employed to define the boundary conditions for numerical simulations of the deformation processes of heterogeneous multi-layer systems composed of microalloyed steel, titanium, or magnesium. Various configurations, conditions, and deformation schemes were applied, which were then replicated in numerical simulations. Rheological models were used in the studies which, through computer simulations, enabled the modeling of interactions between the incoherent components of the microstructure. The primary outcome of the conducted experimental studies and numerical simulations is the ability to assess the heterogeneity of the studied multi-layer systems in terms of their mechanical states and influence on microstructural changes. This heterogeneity additionally arises from the diverse microstructural and rheological characteristics of the investigated materials (BCC vs. HCP), which, in turn, affect the strengthening mechanisms, primarily strain hardening. The results obtained from channel die compression tests were then used in simulations of multi-stage wire drawing, supporting both the design phase and the analysis of the resulting microstructural effects in the studied heterogeneous systems. It was observed that one of the key criteria for designing heterostructured wires from the examined materials is the proper selection of the volume fraction of the components, as well as the deformation history during multi-stage wire drawing, considering interpass heat treatment.
The application of numerical simulations to analyze the forward extrusion process along with the verification of results and tuning of the numerical model
(Wydawnictwa AGH, 2025) Hawryluk, Marek; Dudkiewicz, Łukasz; Marzec, Jan; Tkocz, Roger; Borowski, Jacek; Ficak, Grzegorz; Jóźwiak, Bartosz; Ziemba, Jacek
The paper presents the application of numerical simulations based on the Finite Element Method (FEM) for analyzing and optimizing the extrusion processes of aluminum and lead. These processes are efficient methods for manufacturing critical machine parts and metal components, ensuring excellent mechanical properties. A detailed analysis was conducted on the numerical modeling of the impact of die taper angles on strain distribution and forming forces during co-extrusion. The study found that a 45-degree angle provides optimal deformation conditions, minimizing extrusion forces and reducing the formation of dead zones compared to a 90-degree angle. Numerical simulations, supplemented by technological trials under semi-industrial conditions and image analysis involving the deformation of the coordinate grid, provided key insights into a material flow, strain distribution, and force parameters. The results emphasize the importance of validating numerical models with semi-industrial experiments to ensure accuracy and reliability, as assuming constant tribological conditions may not reflect actual process conditions, including the formation of dead zones for angles greater than 45°. It was only through a thorough analysis of the actual process and the introduction of variable friction coefficients for individual tools that a dead zone was achieved in the modelling. The findings from this research can serve as the foundation for further optimization and adaptation of technological processes, aiming to further enhance extrusion processes through the use of numerical simulations.
The advent of the deep learning evolutionary algorithm EvoDN2 and its recent applications
(Wydawnictwa AGH, 2025) Chakraborti, Nirupam
The evolutionary deep learning algorithm EvoDN2 is an emerging strategy for data-driven intelligent learning and many-objective optimisation capable of handling a large volume of noisy and non-linear data. This article provides the essential details of this algorithm and highlights a number of its recent applications.