PSI - Issue 77

ScienceDirect Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2026) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2026) 000–000 Available online at www.sciencedirect.com Procedia Structural Integrity 77 (2026) 559–566

www.elsevier.com/locate/procedia

www.elsevier.com/locate/procedia

© 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers A multibody system (MBS) of the 4000 kN servo press was developed in SimulationX ® software to study its dynamic behaviour. Components were modelled as rigid bodies connected through linear and revolution joints. The dynamic behaviour of the servo press was assessed under different loading conditions, including without loading, under balanced and unbalanced loading. This allowed the identification of critical regions, regarding vibration, mechanical loading and power losses due to contact between the slide and frame. Additional features, such as pneumatic counterbalancing cylinders and plain journal bearings, were also included in the model. The integration of these simulations with real-time monitoring of the servo press, using several sensors, allows for a more reliable and efficient condition monitoring. By providing a virtual counterpart, the digital twin becomes a valuable tool for understanding the system’s behaviour beyond what can be inferred from sensor measurements alone. Abstract Servo presses spend most of their lifecycle performing cutting and stamping operations, which gradually lead to mechanical deterioration. On top of that, misuse and fatigue can introduce issues which, if left unattended, will cause major equipment failure. The detection of anomalous situations before damage propagation throughout several components, as well as the understanding of their health condition, is crucial for failure prediction. To support this, digital twins can be integrated into maintenance programs to enable real-time monitoring, simulation, diagnosis and prognostics. Digital twin simulations make it possible to visualise the impact of changes in operational or structural parameters. Therefore, this work focuses on the simulation of a real 4000 kN servo press for blanking processes, manufactured by Mecânica Exacta. A multibody system (MBS) of the 4000 kN servo press was developed in SimulationX ® software to study its dynamic behaviour. Components were modelled as rigid bodies connected through linear and revolution joints. The dynamic behaviour of the servo press was assessed under different loading conditions, including without loading, under balanced and unbalanced loading. This allowed the identification of critical regions, regarding vibration, mechanical loading and power losses due to contact between the slide and frame. Additional features, such as pneumatic counterbalancing cylinders and plain journal bearings, were also included in the model. The integration of these simulations with real-time monitoring of the servo press, using several sensors, allows for a more reliable and efficient condition monitoring. By providing a virtual counterpart, the digital twin becomes a valuable tool for understanding the system’s behaviour beyond what can be inferred from sensor measurements alone. International Conference on Structural Integrity Multibody Dynamic System for Servo Press Condition Monitoring Vasco Gomes 1 *, Alexandre B. Santos 1 , Daniela I. M. Azevedo 1 , Tiago M.R.M. Domingues 1 , Susana Dias 1 , Pedro M.G.P. Moreira 1 , Tiago T.M. Soares 2 , António da S. Guedes 2 1 INEGI, Institute of Science and Innovation in Mechanical Engineering and Industrial Engineering, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal 2 Mecânica Exacta, S.A., R. António Gomes da Cruz 34, 4535-438 São Paio de Oleiros Abstract Servo presses spend most of their lifecycle performing cutting and stamping operations, which gradually lead to mechanical deterioration. On top of that, misuse and fatigue can introduce issues which, if left unattended, will cause major equipment failure. The detection of anomalous situations before damage propagation throughout several components, as well as the understanding of their health condition, is crucial for failure prediction. To support this, digital twins can be integrated into maintenance programs to enable real-time monitoring, simulation, diagnosis and prognostics. Digital twin simulations make it possible to visualise the impact of changes in operational or structural parameters. Therefore, this work focuses on the simulation of a real 4000 kN servo press for blanking processes, manufactured by Mecânica Exacta. International Conference on Structural Integrity Multibody Dynamic System for Servo Press Condition Monitoring Vasco Gomes 1 *, Alexandre B. Santos 1 , Daniela I. M. Azevedo 1 , Tiago M.R.M. Domingues 1 , Susana Dias 1 , Pedro M.G.P. Moreira 1 , Tiago T.M. Soares 2 , António da S. Guedes 2 1 INEGI, Institute of Science and Innovation in Mechanical Engineering and Industrial Engineering, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal 2 Mecânica Exacta, S.A., R. António Gomes da Cruz 34, 4535-438 São Paio de Oleiros

* Corresponding author. Tel.: +351 229578710. E-mail address: vbgomes@inegi.up.pt

* Corresponding author. Tel.: +351 229578710. E-mail address: vbgomes@inegi.up.pt

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 10.1016/j.prostr.2026.01.071 2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers