Among non-destructive testing methods, a group dedicated to the assessment of the state of residual stresses can be distinguished. The method of measuring residual stresses using the Barkhausen noise method has many advantages, as evidenced by the number of publications. The residual stresses in metal products are important for the further processing of such metal, such as laser cutting or bending. The results presented in this work are of an experimental nature, and the presented method of calibration of measuring heads shows how various research techniques can be used to correlate results. The research was carried out for structural steel due to the market share of this type of steel. The method can be used to measure the residual stresses in ferromagnetic metal products in order to assess their directions and quantify them. A prerequisite for the use of this measurement method is that the amplitude and geometry of the Barkhausen noise are adequately correlated to the specific values of the state of stress depending on the tested steel grade or other metals. In this study, a method for calibrating measuring sensors for the residual stress measurements is presented, as developed by the authors. The method involved conducting bending tests in both numerical modeling and experimental tests. During the bending tests, changes in the magnetic field (Barkhausen noise waveform) were recorded, taking into account the state of elastic stresses. Correlating the results of the numerical calculations and Barkhausen noise measurements made it possible to determine the quantitative values of the residual stresses in the steel sheets. Thanks to the method used, very accurate measurement is possible, and the obtained results are repeatable.

The aim of this research was to select parameters for the roll pre-leveler to provide sheet metal waviness reduction after unwinding from the coil. Straightening parameters were selected based on the results of numerical simulations with the use of an FEM-based computer program. The material used for research was a hot-rolled sheet metal of grade S235JR + AR with a thickness of 3 mm and width of 1500 mm after unwinding from the coil. A mathematical model was developed to determine straightening roll arrangements in the pre-leveler. It enabled roll arrangement selection and a straightening scheme to be elaborated. The model’s innovative feature was conducting straightening numerical simulations for the real sheet metal geometric models obtained as a result of 3D laser scanning, which increased the accuracy of the numerical calculations.

The paper presents the results of a numerical analysis of the roller straightening process. The study evaluated straightening systems consisting of 5, 7, and 9 rollers. The assessment was based on real data obtained under industrial conditions. The research involved the use of two widely used structural steel grades, namely S235JR and S500MC. As part of the study, an analysis of the anisotropy of sheet properties within the coil volume was also conducted. Additionally, the surface topography of the sheets was analyzed and subsequently used in the numerical simulations. The inclusion of real data regarding both material anisotropy and actual geometry allowed for an increase in calculation accuracy. Furthermore, investigations were carried out to analyze the method of implementing material data into the mathematical model. The work also analyzed the accuracy of the obtained numerical results based on material data from the traditional method of introducing material information in the form of an approximated curve. Numerical studies confirmed by a physical test developed by the authors, which can be easily implemented in industrial conditions, confirmed the research assumptions and literature data. The main advantage of the presented solutions is their relative ease of implementation and use in manufacturing facilities with limited research facilities.