Le domaine général de la thèse est l’analyse de sensibilité de fonctions boîte noire. L’analyse de sensibilité étudie comment la variation d’une sortie peut être reliée à la variation des entrées. C’est un outil important dans la construction, l’analyse et l’optimisation des expériences numériques (computer experiments).Nous présentons tout d’abord l’indice d’interaction total, qui est utile pour le criblage d’interactions. Plusieurs méthodes d’estimation sont proposées. Leurs propriétés sont étudiées au plan théorique et par des simulations.Le chapitre suivant concerne l’analyse de sensibilité pour des modèles avec des entrées fonctionnelles et une sortie scalaire. Une approche séquentielle très économique est présentée, qui permet non seulement de retrouver la sensibilité de entrées fonctionnelles globalement, mais aussi d’identifier les régions d’intérêt dans leur domaine de définition.Un troisième concept est proposé, les support index functions, mesurant la sensibilité d’une entrée sur tout le support de sa loi de probabilité.Finalement les trois méthodes sont appliquées avec succès à l’analyse de sensibilité de modèles d’emboutissage. / The general field of the thesis is the sensitivity analysis of black-box functions. Sensitivity analysis studies how the variation of the output can be apportioned to the variation of input sources. It is an important tool in the construction, analysis, and optimization of computer experiments.The total interaction index is presented, which can be used for the screening of interactions. Several variance-based estimation methods are suggested. Their properties are analyzed theoretically as well as on simulations.A further chapter concerns the sensitivity analysis for models that can take functions as input variables and return a scalar value as output. A very economical sequential approach is presented, which not only discovers the sensitivity of those functional variables as a whole but identifies relevant regions in the functional domain.As a third concept, support index functions, functions of sensitivity indices over the input distribution support, are suggested.Finally, all three methods are successfully applied in the sensitivity analysis of sheet metal forming models.

Incremental sheet forming (ISF) is a flexible process where an indenter moves over the surface of a sheet of metal to form a 3D shell incrementally by a progression of localised deformation. Despite extensive research into the process, the deformation mechanics is not fully understood. This thesis presents new insights into the mechanics of ISF applied to two groups of materials: sheet metals and sandwich panels. A new system for measuring tool forces in ISF is commissioned. The system uses six loadcells to measure reaction forces on the workpiece frame. Each force signal has an uncertainty of ±15 N. This is likely to be small in comparison to tool forces measured in ISF. The mechanics of ISF of sheet metals is researched. Through-thickness deformation and strains of copper plates are measured for single-point incremental forming (SPIF) and two-point incremental forming (TPIF). It is shown that the deformation mechanisms of SPIF and TPIF are shear parallel to the tool direction, with both shear and stretching perpendicular to the tool direction. Tool forces are measured and compared throughout the two processes. Tool forces follow similar trends to strains, suggesting that shear parallel to the tool direction is a result of friction between the tool and workpiece. The mechanics of ISF of sandwich panels is investigated. The mechanical viability of applying ISF to various sandwich panel designs is evaluated by observing failure modes and damage under two simple tool paths. ISF is applicable to metal/polymer/metal sandwich panels. This is because the cores and faceplates are ductile and largely incompressible, and therefore survive local indentation during ISF without collapse. Through-thickness deformation, tool forces and applicability of the sine law for prediction of wall thickness are measured and compared for a metal/polymer/metal sandwich panel and a monolithic sheet metal. The mechanical results for ISF of sheet metals transfer closely to sandwich panels. Hence, established knowledge and process implementation procedures derived for ISF of monolithic sheet metals may be used in the future for ISF of sandwich panels.

The thesis deals with the design of a technological process for the production a rotationally symmetrical component, which is part of the body for the chassis ball joint of a passenger car. Thesis was developed on request and in cooperation with THK RHYTHM Automotive Czech a.s. On the basis of a literary study, a technological process consisting of 10 operations was designed and elaborated. For the prototype production of the component, a four-column hydraulic press SHPFS 250, with a nominal force 2500 kN, was selected and price offer were prepared. For each of ten operations a prototype tool was designed and prepared assembly drawings. To reduce costs, a single die set was designed to allow all tools to be clamped. The total cost of acquisition of the prototype hydraulic press and tools was set at CZK 2,672,950.

The Diploma thesis describes the implementation of innovative production of protective liner to the manufacturing company. The liner is manufactured in sizes of nominal diameter DN 200 - DN 500. The material is low-alloy steel EN 10216-2 10CrMo9-10. For the production innovation, the technology of pipe end flaring by a movable mandrel was chosen. Verification of the functionality of this technology was performed using analytical calculations and numerical simulation of FEM. The results of numerical methods were compared with the results of a practical experiment. The experiment was performed on 5 test specimens with a diameter of 273 mm. The machine device was a hydraulic press with a nominal force of 2000 kN and equipped with pressure and position sensors. The experimentally obtained values of force and the tool path dependence were similar with the values of FEM simulation. The difference in the value of the force in the maximum tool path was 290 kN. The flared diameter was formed to a value of 319 mm. This value corresponds to 16.5% of increased nominal diameter, which is sufficient from design point of view. Non-destructive tests ruled out the presence of crack defects on the flared diameter. According the new set up working procedure was produced the first real part. Significant financial savings of CZK 3.5 - 5.3 million / year were quantified in the technical and economic evaluation. Return on necessary investments is between the 9th - 14th manufactured pieces (approx. 15% of the annual production volume). In conclusion, innovation has promising results and will be issued by the company into the production process.

This master’s thesis presents a proposal for the technology of manufacturing sheet metal part, which is a part of a bicycle wall bracket. The component is made of steel sheet ČSN 11 325 with subsequent surface treatment by galvanizing. Due to the chosen method of manufacturing with a progressive stamping die, the research part is focused on the technology of shearing and bending. Technological calculations were performed for the most suitable production variant, on the basis of which a mechanical press ANDRITZ Metals with the designation KSTU 2000-20-4G-PSE was chosen. Furthermore, the design of the tool itself is presented, which is substantiated by drawing documentation. At the end of the work, a technical and economic evaluation of the produced series of 300 000 workpieces per year is calculated.

The thesis proposes a concept of manufacturing the folding meter lock. The part is made from DC01+LC steel of 0,3 mm thickness. The series size is 100 000 pcs/year. A forming in a progressive combination tool combining shearing, bending and stamping was chosen for the production, based on the analysis of possible solutions. The tool, designed on the basis of literary research of used technologies, produces the part in eleven steps exerting maximal force of 38,5 kN. The production will take place on an eccentric press LEN 40 C. The market price of 3,38 Kč for one piece was established by the technical and economic evaluation.

The project drawn up within the framework of engineering studies in discipline Manufacturing technology (2303T002) presents a proposal for processing a single part – the part is made of sheet steel number S420MC – by blanking, bending and stamping. On the basis of a literary exploration of given problems several variants of processing a part was propounded in order to be made in just one tool. The transfer combined die is fixed in crank press WAINGARTEN ARP 80 with 800 kN nominal force. All functional parts are made of heat treated tool steel number 19 573.3 according to drawing documentation. Lower functional parts of tool (blanking die, stamping die and bending tool) are made as divided.

The aim of this diploma thesis is to propose a production technology of a given part based on technological and economic factors. At first it is found, if the part is producible by fineblanking. The theoretical part of the diploma thesis is concerned with the description of the conventional sheet metal cutting theory, fineblanking theory and bending theory. In the practical part of the diploma thesis, four variants of cut-in plan are dealt with including the selection of the optimal one based on technological and economic calculations. It is the production of a PULL REAR iron made of the steel sheet 11 320.21, thickness of 3 mm and a production run of 75 000 pieces per year.

This thesis submits a proposal production technology of single parts from sheet steel No. 11 305, thickness of 2 mm, made from a semi-finished product with a diameter of 246 mm, production run of 50 000 pieces per year. To manufacture the component a technology of hydromechanical drawing is proposed. On the basis of a literary study and calculations a drawing tool was designed, fixed in hydraulic press LPS 4000. To prepare a semi-finished product, flange trimming, and hole punching, a sheet metal cutting is used.

Based on study of documents supplied by PWO Unitools a.s. and on advices of design office staff, tool for forming flanges was designed. This tool was then manufactured and it has been used for carrying test of creating flanges of various diameters from high-strength steels. During these tests, the following parameters were optimized – force of upper and lower blank holder and the height of the main guides. Threads were created into these drown flanges. These threaded joins were later tested for maximum torque and maximum compressive strength.