PSI - Issue 77

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Gomes et al./ Structural Integrity Procedia 00 (2026) 000–000

560 © 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 Keywords: Multibody Dynamics; Servo Press; Condition Monitoring Vasco Gomes et al. / Procedia Structural Integrity 77 (2026) 559–566

1. Introduction Stamping presses play a critical role in modern manufacturing enabling the execution of a wide range of operations, such as blanking, piercing, bending, and more, on metal components. The development of mechanical servo-driven presses, which combine the flexibility of hydraulic presses with the speed, accuracy and reliability of mechanical presses, enabled the adaptation to different forming processes, leading to improved process conditions and increasing productivity (Osakada et al., 2011). One major feature includes the possibility of employing different types of motions to the slide. Due to the continuous operation of this type of equipment, early detection of issues is essential, since minor faults tend to worsen over time, potentially compromising its performance and the quality of the manufactured product. Additionally, time based preventive maintenance lacks the flexibility and efficiency sometimes required in industrial environments (Zhong et al., 2023). Therefore, accurate failure prediction is critical to avoid unexpected downtime, costly repairs, and production losses. In order to address these challenges, the integration of digital twins into maintenance programs presents itself as a promising possibility. The “Digital Twin” concept was first introduced by Dr. Michael Grieves, in 2002, in the presentation “Conceptual Idea for product lifecycle management (PLM)”, where it was introduced the possibility of connecting a “real space” and a “virtual space” (Grieves, 2016). From then on, this concept has evolved and currently, it could be described as a specifically constructed computational living model, that changes as it receives data updates, and provides crucial information to the decision-making, being possible to employ it at different stages of a product's lifecycle (product design, manufacturing, distribution, maintenance and recycling) (Tao et al., 2019). A Digital Twin is capable of providing different service tools, categorised into four main types: platform, simulation, optimization, and diagnostic/prognostic (Qi et al., 2021). Focusing on the simulation tools, they can involve multiple areas, such as kinematics, structural analysis and virtual testing, and one software that can be used is SimulationX ® (as reported by Jomartov et al. (2021) and Xu et al. (2018)), that can be used for digital twin modelling and offers extensive libraries, as well as the option to export and integrate the model into a dashboard for analysis. Thus, this software was selected and used to develop the dynamic model of a straight side two-point servo driven press, capable of achieving a maximum tonnage of 400 ton. The approach selected consisted of establishing a multibody simulation (MBS) model, which is composed by rigid bodies interconnected in an arbitrary arrangement by different types of joints and by force elements (Wittenburg, 2008). The servo press models were therefore built according to the 3D CAD data of the press supported by Mecânica Exacta. Due to limitations regarding the software license, two models were created: a 3D model and a 1D model of this press. These will be firstly explained, along with their major features and distinctions, before the results are analysed and conclusions drawn.

Nomenclature MBS multibody simulation HOLP hydraulic overload protection FMU functional mockup unit CAD computer-aided design