Modelling and characterization of materials and manufacturing processes

 Optimal mechanical design of machines and components:

Design, analysis and theoretical and experimental evaluation of machines and components, adding value from the conception of the idea to the manufacturing process, through calculation (resistance, fatigue), dynamic analysis (vibrations), redesign, design of detail, prototyping and even the construction of test benches when required. Specialization in machines with rotating elements.

 Component production: 

• Processes and thermomechanical treatment of steel

• Prediction of mechanical properties and reliability of products

• Powder metallurgy and additive manufacturing

• On-line and off-line manufacturing quality control through non-destructive testing techniques

 Life prediction based on mechanical reliability:

Experimental characterization and modeling of fracture and fatigue (and creep-fatigue) under complex states of mechanical and thermal load, including residual stresses. Design of experiments for early crack detection and component testing. Analytical models and based on finite elements (cohesive models, XFEM and others of own development) to estimate the remaining life of components and to establish strategies for predictive maintenance and decision making.

 Mathematical models of materials and simulation of cold forming processes:

The trend in different industrial sectors (automotive, energy, construction ...) is to reduce the weight of the components and the use of raw materials using a higher-grade (stronger) starting material with less thickness.

Using these grades requires finer control of the forming process and a tighter process window to avoid formability and / or tool breakage problems. The design of the forming process for these new grades is carried out based on previous experience and a methodology based on trial-error that increases prototyping costs, lengthens lead times and does not guarantee optimal processing conditions. Study robust computational tools that allow to accurately predict springback and formability phenomena in forming processes.

This includes:

• The construction of physics-based material models that accurately describe the elastic-plastic anisotropy of the starting material.

• The construction of anisotropic damage models that allow predicting the conformability of the material.

• The development of computational tools based on reverse engineering that allow designing an optimal shaping strategy and tooling design.