Over the last decades, lasers have been adopted in a wide spectrum of sheet metal processing applications and they represent a core production technology of modern process lines. Nevertheless, challenges, which cannot be opposed by established system technology, arise for instance due to new materials and material pairings, the electrification in the automotive industry as well as the demand for traceability in the digital production process. Therefor these challenges state some of the main driving forces for new technologies in the field of laser materials processing. Due to this, for example new beam sources, more advanced processing optics, but also new sensing technologies are developed and made industrially available. One example for this are the variety of solutions for increasing the weldability of copper or the increased number of remote processing applications. The novel technologies not only serve the demand from industry, they also open up new opportunities. For example, the faster beam deflection allows avoiding defects by beam oscillation during the process. In addition to that, the available system technology can be used to reach not yet used process regimes to realize processes with an increased economic and ecologic efficiency like remote cutting. In the near future uprising technologies, like beam shaping, will open up a complete field of opportunities by making additional degrees of freedom available for the realization of innovative laser applications in sheet metal processing.

Prof. Michael Schmidt

Professor Schmidt was born in Coburg in 1969 and studied electrical engineering at the Friedrich-Alexander-Universität Erlangen-Nürnberg. From 1997 on, he worked as research assistant at the Chair of Manufacturing Technology in the field of laser materials processing before he switched to the Bayerisches Laserzentrum GmbH as senior manager development / production in 2001. He finished his doctoral thesis on “Process control of laser spot welding in electronics production” in 2002 and became a member of the executive board of the Bayerisches Laserzentrum GmbH. Since January 2005, he leads the Bayerisches Laserzentrum GmbH as a managing director. When the Institute of Photonic Technologies was founded in March 2009, he became full professor at the University of Erlangen-Nuremberg.

Although the creativity of sculptors plays an important role in the development of new proof coins for collection purposes, it is nowadays impossible to produce innovative collector coins without a serious commitment to technological development. The convergence of recent trends in numerical simulation of coin minting, in advanced coin minting presses and in the utilization of other materials than those usually taken from groups 10 and 11 of the periodic table are pushing the limits of innovation in coin minting. The consequence of all this is that coin minting has evolved to such a level of complexity that some of the geometries, materials and techniques used in newly minted proof coins would simply be out of consideration two or three decades ago.

With this in mind, it is the purpose of this presentation to provide a state-of-the-art review in science and technology of coin minting and to introduce some of the actual trends in the production of collection coins. Special emphasis is placed on innovative design techniques, new materials and joining processes. Two examples will be comprehensively discussed. Firstly, the development and application of finite element based design procedures for correcting the coining die profiles and extending their service life. Secondly, the development of a new polymer-metal coin that is produced by combination of coin minting and joining by forming in a single die stroke. The utilization of coining disks made from sandwich composites with the purpose of obtaining new aesthetic effects and/or incorporating advanced security features will be also discussed.

Prof. Paulo A. F. Martins

Paulo Martins is professor of manufacturing at Instituto Superior Técnico, University of Lisbon, Portugal. He obtained a PhD in mechanical engineering from Instituto Superior Técnico in 1991, the habilitation in mechanical engineering from Instituto Superior Técnico in 1999 and the degree of doctor technices honoris causa from the Technical University of Denmark in 2018.

He was president of the scientific board at Instituto Superior Técnico from 2009 to 2012 and he is president of the school council of Instituto Superior Técnico since 2017.

His research interests are focused in metal forming and joining technologies and he is co‐author of six books, several international patents and 400 papers in international journals and conferences.

The optimization of products and processes, as well as short development times, requires intensive use of numerical frameworks and tools for virtual testing. There is a multitude of software packages designed to help engineers, mostly resorting to Finite Element Analysis (FEA) with the common aim to provide accuracy and simultaneous efficiency and offering a diverse library of finite elements and material laws for distinct simulation needs. This talk provides an overview of common numerical pathologies and issues related to the simulation of sheet metal forming processes. Applied examples will show the importance of carefully choosing some model and simulation parameters in order to obtain results in a fast and reliable way.

Prof. Ricardo Alves de Sousa

Ricardo Alves de Sousa (São Paulo, 7th October, 1977) is currently Assistant Professor with Habilitation at the Department of Mechanical Engineering, University of Aveiro and member of the Center of Mechanical Technology and Automation (TEMA) research unit. His main interests are related to Computational Mechanics, either by modelling technological processes and materials. He has more than 80 scientific contributions either in papers, book chapters and books, and he is author of 3 patents. In 2011, he received the international scientific ESAFORM (European Association of Material Forming) career prize. In 2013 he received the Innovation Prize from APCOR (Portuguese Association for Cork Material), and in March of 2015 he was selected researcher of month at the University of Aveiro.

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XXL Profile Bending

Bending XXL boom profiles and large radius shells for markets such as yellow goods, transportation and offshore is traditionally a highly labour-intensive process that involves multiple setups and part handlings to achieve an accurately formed part. As such, productivity suffers and the risk for error and operator injury is high. Though bending technology has made significant strides in reducing press brake set up time and improving the accuracy and repeatability of forming, these jobs remain a challenge fundamentally because of their XXL size. The advent of new high-strength materials with tensile strengths up to 1,300 MPa and higher, small batch production, tight tolerances and falling skill levels in the work shop have added to the challenges of XXL bending.

In this presentation we examine the current demands and trends in XXL bending and introduce an award-winning adaptive bending solution, Synchro-Form. Synchro-Form addresses the challenges of large-profile bending, making it possible to bend large profiles with consistent accuracy, at high throughput and with minimal operator intervention. This next-generation adaptive bending technology is changing XXL bending. By using an in-process quality management system to measure the accumulated angle and compensate for angle deviation in the bends that follow, this advanced technology can improve productivity of large profile bending up to 50% or more, depending on the specific profile. An example of an XXL bending application in the aerospace sector will be featured, detailing Synchro-Form technology in action.

Steven Lucas

Trained in electromechanical engineering (VHTI – Kortrijk), Steven Lucas began his career 24 years ago at LVD, a renowned Belgian manufacturer of press brakes and shears, punch presses, laser cutting machines, software and modular automation. Steven advanced from a field engineer position with LVD’s World Service team to international Sales Manager. Because of his solid experience in bending technology and proven skills in key account management, he was appointed Press Brake Product Manager in 2008. In this capacity, Steven is responsible for the international press brake sales team and is involved in sales activities with key accounts across the globe. Integral to his role is keeping abreast of market trends and technology.

Steven’s strong interest in new technologies and close work with customers has often incited LVD to develop and implement technical innovations, such as the customized Synchro-Form press brake, especially developed for Kawasaki Heavy Industries and their work with aviation giant Boeing. As a result, LVD is recognized as a world leader in bending.

Due to the increasing customer demands on quality, safety, lightweight and design, more and more complex sheet metal parts have to be produced. In order to overcome the resulting challenge of time pressure, Finite Element Analysis are of utmost importance for production technology. For those models a profound knowledge about the material is essential. One of the main objectives in sheet metal forming simulations is the feasibility prediction limited by localized necking.

The forming limit Curve (FLC) is a conventional model to estimate the forming limits of sheet metals for proportional loading conditions in Finite Element Analysis. Previous studies found that a standard linear Forming Limit Curve is not suitable for predicting the influence of non-proportional load histories. Models to address this problem are i.a. the Generalized Forming Limit Concept (GFLC). Those models require reliable databases and profound knowledge about the material.

The Generalized Forming Limit Concept is purely based on measurable data, which is why no material model has to be used to assess complex strain paths regarding formability. Nevertheless, the bi–linear material tests, which are needed as database, e.g. Nakajima tests or cruciform specimens, have to guarantee precise results. By analyzing an acceptable number of bi–linear experiments it is possible to calibrate the phenomenological GFLC model. Therewith an arbitrary load history can be evaluated with respect to localized necking. The cost effectiveness of the approach is given through the possibility of scaling the results. Non–proportional load histories of materials within the same material class can be estimated without any individual experiments for model fitting. Only a linear forming limit curve is needed.

Prof. Wolfram Volk

Prof. Dr.-Ing. Wolfram Volk studied physics and mechanics at TH Darmstadt and received his diploma in 1994. His work as research associate under the direction of Prof. Dr.-Ing. Wolfgang Ehlers led to his Ph. D. in 1999. After that he worked in different positions in the fields of metal forming with focus on simulation, product and process planning as well as concept development at BMW AG in Munich. Since April 2011, Prof. Volk holds the Chair of Metal Forming and Casting as a full professor at the Technical University of Munich. The chair focuses on the three production processes of casting, blanking and metal forming. Prof. Volk has about 40 scientists at his institute working on research projects, which vary from fundamental research to industrial application. He became a member of CIRP and acatech (National Academy of Science And Engineering). Since July 2016 he is also a member of the board at the Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV.