Research enhances simulations of manufacturing processes in the automotive industry

Erik Lundholm, PhD student and engineer at Gestamp Hardtech, is conducting research on simulating press hardening, a manufacturing technique developed in Luleå and widely used in the automotive industry. Through advanced computer models, the entire hardening process of steel components can be predicted, where heat conduction, the material’s microscopic structure, and its mechanical properties all interact.

Press hardening is a process where steel is heated to over 900 degrees Celsius, changing its microscopic structure and making the material extremely soft. As the steel is shaped and rapidly cooled, it hardens and becomes a very strong and durable material, making it ideal for safety-critical components in cars. The technique, developed in Luleå in the 1970s, has become a global standard in the automotive industry.

What makes press hardening so interesting from a research perspective is its complexity. To simulate the entire process, advanced models are required to predict how heat spreads through the steel, how the material’s structure changes at the microscopic level, and how these changes affect the strength of the final components.

Erik Lundholm’s research at LTU is part of the PROChain project, a collaboration between the university and industry. His work focuses on understanding how the material’s previous manufacturing history affects the hardening process. Since certain properties of the steel remain from earlier production stages, even after it has been reheated, these factors must be included in the simulations to accurately predict the final result.

The research is interdisciplinary, combining expertise in programming, materials science, and solid mechanics. With improved simulation models, the automotive industry can optimise its production and develop even safer and more durable components for the vehicles of the future.