The production of ultra-high strength automotive components requires a multi-directional approach. Hot stamping combines both forming and heat treatment processes to obtain a usually martensitic structure of complicated shaped automotive parts. The preparation for production using hot stamping must involve the latest methods of numerical analysis of both temperature changes and forming, which are applied for an increasing range of materials used. In this paper, the current state of knowledge about the basics of hot stamping, used technological lines, and the current state of material used with applied heat treatments and possible coatings have been reviewed. Moreover, the numerical modeling process has been described. The most important aspects of process automation, including the use of digital twins for simulation and optimization of operational kinetics of the robots accomplishing the production process, analysis and minimization of time of production cycles, and searching for weak operational points of the control systems and for real time visualization of operation of complete line, are considered. The digital twins and corresponding numerical models enable the symmetrical design of real production lines. The details of heat treatment profiles with so called tailored zone heat treatment are provided. Hot stamping is a dynamically developing technology as evidenced by the increasing range of materials used, also from the 3rd generation of advanced high strength (AHSS) steels. It starts to combine forming of symmetric or asymmetric elements with more complex heat treatment processes as required for dual phase (DP) stainless steels or the newest generation of high-strength and ductile medium-manganese steels.

Vibration monitoring is essential for maintaining the optimal performance and reliability of industrial machinery, which experiences dynamic forces and vibrations during operation. This study delved into a comprehensive analysis of vibration monitoring in hydraulic presses, utilizing advanced measurement systems equipped with accelerometers. The proposed system included a three-axis accelerometer, data acquisition unit, and dedicated measurement software, facilitating the precise monitoring and analysis of vibrations. The influence of the sensor placement and sampling frequency on the measurement results was examined. A time and frequency analysis of the recorded measurements was performed. The results demonstrated the correlation between vibration levels and various production parameters, such as the number of parts simultaneously produced and press pressure. These findings underscore the potential for vibration measurement as a pivotal component in controlling production parameter settings.

A design study of automatic line-to-production of a new generation of car body structures compliant with the Industry 4.0 concept is described in this paper. The line is based on the hot-stamping technology of components of a car body structure from 22MnB5 steel sheets. Additional modules of the designed production line are: laser-trimming station, station to completion (kitting-up), and spot-welding station of the subassemblies. Technical requirements to be complied with by such line and scheme of exchange of information between modules of the line were defined. The conclusions were formulated.

One of the important steps in the design of hot stamping tools is the analysis of their cooling system. This article presents an authorial, two-stage approach to solving this problem. The first stage consisted of a series of simulations of the hot stamping process in the Autoform package, with initial selection of shape and arrangement of cooling channels. These results allowed for the design of the tool for which the coupled thermal-flow analysis was carried out. The correctness of the adopted design assumptions has been confirmed by experimental tests. A trial series of drawpieces made in production conditions meet the requirements for hardness, mechanical properties, and appropriate microstructure. The presented procedure has become the practice of the drawpiece producers.

The combination of complex geometry and martensitic microstructure, characterized by ultrahigh strength and hardness, can be obtained in a single hot stamping process. However, this technology requires a multifaceted approach, allowing for an effective and efficient design process that will ensure the elements with the desired properties and shape are produced because of the high tool cost. This paper presents a comprehensive case study of the design process, simulation and experimental evaluation of the hot forming of an automotive door beam. The U-shaped beam designed with CAD was analyzed using the finite element method in the Autoform v.10 software. The modeling process included: a shape definition of the flat blank; a FEM analysis and design of the die, punches, and clamps; and a forming and quenching simulation. The results covered visualization of the forming and quenching stages for different variables including a forming limit diagram; a distribution of the drawpiece thinning; and a diagram showing the hardness of the drawpiece and its microstructure. Based on the results, a full-size tool for hot stamping was first modeled in the CAD and next manufactured. The tool was used to produce an initial sample series that was used to investigate the conditions for continuous use of the tool. One of the produced hot-stamped products was investigated for its hardness and microstructure, which exhibited a beneficial and fully martensitic microstructure with high hardness of above 400 HV1.

In this article, an application of a three-dimensional scanner for building a special diagnostic stand is described. An experimental method of detection of material defects is discussed. The considered defects are connected with cooperation of particular surfaces of machine parts. In the discussed experiments, particularly the dimensions of pitting holes can be evaluated. Availability of laboratory facilities required that the investigations were performed using geared wheels. The three-dimensional model which represents a degenerated surface, obtained based upon the diagnostic measurements, was compared with the pattern of an undamaged surface. The latter was generated by means of our pre-processor. The pre-processor enables generation of files which are compatible with the majority of the computer-aided design system formats. Therefore, the analyses were performed by means of commercial system inventor and computer-aided three-dimensional interactive application.