In sheet metal forming manufacturing operations the use of servo presses is gaining more interest due to the opportunity to improve process performance (quality, productivity, cost reduction, etc.). It is not yet clear how to proceed in the engineering process when this type of operating machine is used to achieve the maximum possible potential of this technology. Recently, several press builders have developed gap- and straight-sided metal forming presses adopting the mechanical servo-drive technology. The mechanical servo-drive press offers the flexibility of a hydraulic press with the speed, accuracy and reliability of a mechanical press. Servo drive presses give the opportunity to improve the productivity of process conditions and improve the quality of stamped parts. Forming simulation and numerical optimization can be useful tools to define beforehand the optimal process parameter set-up in terms of servo press downward curve properties. This is done by carrying out a sensitivity analysis of the forming parameters having influence on said curve. The authors have developed a numerical methodology able to analyze the influence factors, for comparison with the degrees of freedom made available by the usage of a servo press, in terms of stroke profile management, to obtain an optimized process parameters combination.

Selective Laser Melting (SLM) is an attractive Additive Manufacturing (AM) technology for the fabrication of metallic components with complex structures and high performances. This process fulfills the goals of sustainable production by reducing material waste, optimizing product topology, and recycling metallic powder. Aluminum alloys exhibit also sustainable performances being lightweight and recyclable. Al-Si10-Mg alloy is suitable for SLM processing due to its good castability, good strength, wear, and corrosion resistance. However, the laser processing of aluminum alloys to date needs to be optimized. In this study, the authors have analyzed the role of close values of heat input on microstructure and defects (Electron and Optical microscope, DRX analysis), porosity (optical microscope and X-ray tomography), melting pool geometries (both in transversal and longitudinal sections of the samples) and mechanical performance (hardness and tensile test) of Al-Si10-Mg samples. The results have shown that even at very close values of energy density, the microstructure and properties of the samples differ from each other.