This paper reports the results of theoretical and experimental work leading to the construction of a dedicated finite element method (FEM) system allowing the computer simulation of physical phenomena accompanying the steel sample testing at temperatures that are characteristic for integrated casting and rolling of steel processes, which was equipped with graphical, database oriented pre- and postprocessing. The kernel of the system is a numerical FEM solver based on a coupled thermomechanical model with changing density and mass conservation condition given in analytical form. The system was also equipped with an inverse analysis module having crucial significance for interpretation of results of compression tests at temperatures close to the solidus level. One of the advantages of the solution is the negligible volume loss of the deformation zone due to the analytical form of mass conservation conditions. This prevents FEM variational solution from unintentional specimen volume loss caused by numerical errors, which is inevitable in cases where the condition is written in its numerical form. It is very important for the computer simulation of deformation processes to be running at temperatures characteristic of the last stage of solidification. The still existing density change in mushy steel causes volume changes comparable to those caused by numerical errors. This paper reports work concerning the adaptation of the model to simulation of plastic behavior of axial-symmetrical steel samples subjected to compression at temperature levels higher than $1400°C$. The emphasis is placed on the computer aided testing procedure leading to the determination of mechanical properties of steels at temperatures that are very close to the solidus line. Example results of computer simulation using the developed system are presented as well.

The subject of the presented paper is the modeling of strain-stress relationship, which is the main mechanical property characteristic of the behavior of steel subjected to plastic deformation. The major challenge of the research is the temperature of the deformation, which significantly exceeds the hot rolling temperature range. This paper presents the results of work leading to the development of a rheological model describing the phenomena accompanying the deformation of 18G2A grade steel at temperature $1420°C$ and higher. Such temperature is a characteristic of the central parts of steel strands subjected to latest, very high temperature rolling technologies such as integrated rolling and casting processes. Rheological models have crucial influence on the results of the computer simulation of the mentioned processes. The methodology of yield stress curves development requires high accuracy systems of tension and compression test simulation. Hence, the proposed testing procedure is related to dedicated hybrid finite element method system with variable density, which was developed by the authors. The experimental work has been done using the Gleeble® 3800 thermomechanical simulator in the Institute for Ferrous Metallurgy in Gliwice, Poland. The testing machine allows the physical deformation of samples while solidification of their central part is still in progress. The essential goal of the simulation was the computer reconstruction of both temperature changes and strain evolution inside a specimen subjected to simultaneous deformation and solidification. In order to verify the predictive ability of the developed rheological model, a number of compression tests using Gleeble® 3800 simulator have been done, as well. The comparison between the numerical and the experimental results is also a part of the presented paper.

In this study, artificial neural networks were used to predict the plastic flow behaviour of S355 steel in the process of high-temperature deformation. The aim of the studies was to develop a model of changes in stress as a function of strain, strain rate and temperature, necessary to build an advanced numerical model of the soft-reduction process. The high-temperature characteristics of the tested steel were determined with a Gleeble 3800 thermo-mechanical simulator. Tests were carried out in the temperature range of 400–1450 °C for two strain rates, i.e. 0.05 and 1 s⁻¹. The test results were next used to develop and verify a rheological model based on artificial neural networks (ANNs). The conducted studies show that the selected models offer high accuracy in predicting the high-temperature flow behaviour of S355 steel and can be successfully used in numerical modelling of the soft-reduction process.

The paper presents the numerical and experimental results of research aimed at determining the influence of hardness in the range of 50–90 Shore A of layered tools composed of elastomeric materials on the possibility of forming Inconel 625 nickel-based alloy sheets. A stamping die composed of 90MnCrV8 steel (hardness 60HRC) was designed for forming embosses in drawpieces, ensuring various stress states on the cross-section of the formed element. The principle of operating the stamping die was based on the Guerin method. The finite-element-based numerical modelling of the forming process for various configurations of polyurethane inserts was also carried out. The drawpieces obtained through sheet forming were subjected to geometry tests using optical 3D scanning. The results confirmed that, in the case of forming difficult-to-deform Inconel 625 Ni-based alloy sheets, the hardness of the polyurethane inserts significantly affected the geometric quality of the obtained drawpieces. The assumptions determined in numerical simulations were verified in experimental studies. Based on the test results, it was concluded that the selection of polyurethane hardness should be determined by the shape of the formed element. Significant nonuniform sheet metal deformations were also found, which may pose a problem in the process of designing forming tools and the technology of the plastic forming of Inconel 625 Ni-based alloy sheets.

The paper presents the numerical and experimental results of research aimed at determining the influence of hardness in the range of 50-90 Shore A of layered tools made of elastomeric materials on the possibility of forming Inconel 625 nickel-based alloy sheets. A stamping die made of 90MnCrV8 steel (hardness 60HRC) was designed for forming embosses in drawpieces, ensuring various stress states on the cross-section of the formed element. The principle of operating the stamping die was based on the Guerin method. Finite element-based numerical modelling of the forming process for various configurations of polyurethane inserts was also carried out. The drawpieces obtained by sheet forming were subjected to geometry tests using optical 3D scanning. The results confirm that in the case of forming difficult-to-deform Inconel 625 Ni-based alloy sheets, the hardness of the polyurethane inserts significantly affects the geometric quality of the obtained drawpieces. The assumptions made in numerical simulations were verified in experimental studies. Based on the test results, it was concluded that the selection of polyurethane hardness should be determined by the shape of the formed element. Significant non-uniform sheet metal deformation was also found, which may pose a problem in the process of designing forming tools and technology of plastic forming of Inconel 625 Ni-based alloy sheets.