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The uncertainties of modern, adaptable sheet metal forming systems are classified into model errors and disturbances. To improve the control of production, disturbances in the forming process need to be reduced. For this purpose, a new data flow system was introduced. It connected the data flow of all influencing material parameters into the “material property control function”. To control on-line the forming production line and acquire necessary material data, an indentation test was implemented. The main parameters to follow in this test are pile-up or sink-in values after the embossing of the ball-shaped tool into the material where the innovative approach of fully anisotropic material description was used. To set-up an optimal indentation test, parametric studies were performed with material data of AW 5754-H22. Finite element simulations were used to evaluate the influences of indenter diameter, contact friction and forming history of used the material. Fully anisotropic material behaviour was considered. Novel to this approach were a) the linking of the linear correlation of pile-up with the indentation depth described by gradient k, and b) the linking of gradient k with different pre-strains by a new power function.

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A precise production of sheet metal parts has always been a main goal in press shops. Highest quality demands are required especially in automotive production. Unfortunately, even today, the production is not optimal due to an ineffective approach to the springback compensation. Springback results in geometrical shape inaccuracies of the obtained product. Based on the current approach, excessive time and financial costs emerge due to corrections on the press tools. However, these corrections do not always lead to a better accuracy of the stampings. The main objective of the research is to design a modified solution of the current approach. The modified solution is designed as a methodology with a focus on the analysis and compensation of the springback with a help of a numerical simulation. To achieve the main goal, smaller sub-goals are employed. These sub-goals, or rather experiments, mainly focus on parameters, which, more or less, influence the springback phenomenon. The designed methodology is verified with real car body parts and is carried out with a help of the department of the press tools design in ŠKODA AUTO, a.s. There, the methodology is used for improving the accuracy of the stamping process of the car body parts and for improving the quality of the final product.

Due to environmental concerns and safety standards in the automotive industry, the development of durable and lightweight cars has become an important topic. Lowering the weight of the car body has become a crucial topic for all manufacturers, regardless of using combustion, electric or hydrogen engines. To fulfil this need a material with a higher strength to weight ratio must be used. Dual-phase steels seem to provide the right combination of mechanical properties for the production of particular car body panels. The goal of this research is to develop robust production of the fifth door part from HCT500X steel (DP500). The goal of this article is also to depict the forming of the selected part and the fifth door assembly for 4th generation of ŠKODA Octavia. Numerical simulation is accomplished within the AutoForm Forming R8 and AutoForm Assembly R9 solutions. Different aspects influencing numerical simulation accuracy and topics relevant to the production chain are discussed in this article. This research is carried out in cooperation with ŠKODA AUTO, a.s.