1. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
01

2. index
F u n d a c i ó c T M
03
06
c e n T r e T e c n o l ò g i c
GreetinGs from the President
08 Who are We?
orGanisation
14 Professional team
18 What does fundació
ctm centre tecnolòGic do?
20 areas of Work
77
area of materials technoloGY
area of forminG Processes
96
area of simulation and innoVatiVe desiGn
area of enVironmental technoloGY
area of suPPort to innoVation
116 area of enerGY
128
most outstandinG ProJects
PuBlications, conGresses and thesis
134 headlines 2010
138
international unit
BioenGineerinG diVision
140 QualitY at the fundació ctm
148
aGreements
economic rePort
152 clients
154
future stePs
neW BuildinG
157 02

3. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
1 greetings from
the President
Josep Camprubí
i Duocastella
03

4. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
GREETINGS
FROM THE
W
PRESIDENT
e leave behind the year 2010, a year full of
opportunities that have taken shape; of ideas
that have turned into projects, of initiatives that
have borne fruits, of efforts that have become successes. We
are talking about opportunities, ideas, projects, initiatives and
successes that account for the daily routine of the centre that
seeks excellence starting from rigorous and methodical work and
also for the systematic research work on ambitious long-range
milestones. It has been a year in which Fundació CTM Centre
Tecnològichas had many chances for showing the scope of its
scientific potential and its technological expertise.
The fact is that in the past few months, Fundació CTM Centre
Tecnològic has carried out very significant projects both
because of their dimensions and their complexity. FORMA0 is
the project that has had a greater media impact nevertheless
and fortunately, there have been many other projects at the
same level of academic and professional demand. We have
taken advantage of every research line, every assignment and
every new objective for testing and showing the capacities of
Fundació CTM Centre Tecnològic. There have been many
acknowledgements throughout the city and the region.
04

5. President’s greetings
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
On the other hand, the year that we leave behind has allowed
us to fine-tune the schedule for the moving of the centre and
all its human and technical units to the Parc Central. Once
we have gone beyond the stage of willing, of the creation of
alliances and the search for support, the time for realisation has
come, for preparing the facilities and getting ready for taking
advantage of the boost of a change, not only of location but
also of horizons. Parc Central´s capacity for attracting intensive
economic activities in the use of knowledge and technology is
closely related with Fundació CTM Centre Tecnològic´s potential
for offering advanced services, leading high level scientific and
technological projects and being the connecting link with other
excellent centres in the field of research and innovation.
Finally, I would like to highlight Fundació CTM´s crucial role
in the awarding of the distinction of “city of science and
innovation” to Manresa. The organisation holds many of the
virtues that the award acknowledges: the will for making the
local productive model progress towards a more intense use
of knowledge; the combination of efforts and resources of
different public and private actors; the long-term vision that
combines with an everyday work committed with excellence;
the firm vocation for becoming present in the global economy
taking advantage of the productive know-how of the business
network of the area. Altogether, a great asset for the city and
the region both because of the actual capacities and the
future potentials.
05

6. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
Who
are
we?
06

7. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
WHO ARE
T
WE?
he Fundació CTM Centre Tecnològic is a non-profit
private foundation. Its aim is to efficiently contribute
to the improvement of competitiveness and to the
technological development of companies by providing
specialised services and carrying out R+D + IT projects.
The team of the Fundació CTM Centre Tecnològic works for
companies, organisations and institutions in the fields of Materials
Technology, Simulation and Innovative Design, Forming Processes,
Environmental Technology, Support to Innovation and Energy.
The Fundació CTM Centre Tecnològic is part of the net of
technological centres of the Generalitat de Catalunya (XCT) with
registration number CT03/04; it is registered in the CICYT as
Technological Innovation Centre (CIT) number 46 and it is also
registered as OTRI (Oficina de Transferencia de Resultados de
Investigación- Office for Transference of Research Results) by the
Ministry of Education and Science with number 158.
The Fundació CTM Centre Tecnològic, together with other centres
of Catalonia, has participated in the creation of ACT (Association of
Technological Centres) over which Fundació CTM Centre Tecnològic
first presided.
The Fundació CTM Centre Tecnològic is a member of TECNIO,
a brand created by ACC1Ó which agglutinates the main expert
agents in applied research and technological transfer of Catalonia.
07

8. Who are we?
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
organisaTion
The areas of activity of the Fundació CTM Centre Tecnològic in
2010 have been: Area of Materials Technology, Area of Simulation
and Innovative Design, Area of Forming Processes, Area of
Environmental Technology, Area of Support to Innovation and
Area of Energy.
The organisation of the centre remains as follows:
download
organisation F u n d a c i ó
c e n T r e
c T M
T e c n o l ò g i c
chart
gENERAL
MANAgER
J.M. Prado
INTERNAL
SALES MANAgEMENT
MANAgER DIRECTOR SCIENTIFIC
J. Martí X. Codinach MANAgEMENT
J.M. Prado
J. de Pablo
hEAD OF
MARkET
RESEARCh
X. Vicas
hEAD OF hEAD OF hEAD OF hEAD OF hEAD OF hEAD OF
ACTINIDES COATINgS TRIbOLOgY MICROSTRuC- STEEL ShEET TEChNO-
J. de Pablo J. Caro M. Vilaseca TuRES AND bEhAvIOuR LOgICAL
MEChANICAL T. Lara SERvICES
PROPERTIES C. Abad
S. Molas
hEAD OF
INNOvATIvE
PRODuCTS hEAD OF MANAgE-
X. Vicas MANRESA´S MENT OF
LAbORATORY PROjECTS
N. Bahí A. Beltrán
S AN S
NI CI
AN NI CI
AN S TE Ch TE Ch
NI CI EC T EC T
TE Ch PR Oj PR Oj
EC T AN S AN S
PR Oj NI CI NI CI
RY TE Ch RY TE Ch
RATO RATO
CI AN S LA bO LA bO
TE Ch NI
E
RATIv
NI ST
AD MI
AN S AN S AN S AN S
NI CI NI CI NI CI NI CI
TE Ch TE Ch RY TE Ch TE Ch
EC T EC T RATO EC T hEAD OF bIO-
PR Oj PR Oj LA bO PR Oj ENgINEERINg
DIvISION
S. Idelsohn
08

9. Who are we?
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
general Manager
Dr. Jose M. Prado
Manager of the area of Materials technology
Dr. Daniel Casellas
Manager of the area of Environmental technology
Dr. Miquel Rovira
Manager of the area of support to innovation
Mr. Antoni Fargas
Manager of the area of simulation and innovative design
Dra. Ma Dolors Riera
Manager of the area of Forming Processes
Dr. Jose Ma Cabrera
Manager of the area of Energy
Dr. Luis Romeral
commercial Manager
Sr. Jordi Martí
internal Management director
Sr. Xavier Codinach
scientific Management
Dr. Jose M. Prado
Dr. Joan de Pablo
09

10. Who are we?
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
goVerning Bodies
Board of trustees
President
Most Illustrious Mr. Josep Camprubí Duocastella
CITY COuNCIL OF MANRESA
Vice-president
Most Excellent Mr. Antoni Giró Roca
UNIVERSITAT POLITÈCNICA DE CATALUNYA
second Vice-president
Mr. Manel Rosell Martí
CAIXA D’ESTALvIS DE MANRESA
secretary
Mr. Josep Alabern Valentí
COL·LEgI OFICIAL D’ENgINYERS INDuSTRIALS
Members
CITY COuNCIL OF MANRESA
CAIXA D’ESTALvI S DE MANRESA
CAMbRA DE COMERC I INDuSTRIA DE MANRESA
COL·LEgI D’ENgINYERS TECNICS INDuSTRIALS DE MANRESA
CIDEM
COL·LEgI D’ARQuITECTES DE CATALuNYA
COL·LEgI OFICIAL D’ENgINYERS INDuSTRIALS
CONSELL COMARCAL DEL bAgES
CONSTRuCCIONS SALIDO, S.A.
FEDERACIÓ D’EMPRESARIS CATALuNYA CENTRAL
FuNDACIÓ uNIvERSITÀRIA DEL bAgES
PIMEC
UNIVERSITAT POLITÈCNICA DE CATALUNYA
vILARDELL PuRTÍ, S.A.
010

11. Who are we?
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
executive committee
The Fundació CTM Centre Tecnològic´s board of Trustees
appointed the following representatives of different companies
and institutions to make up the Executive Committee:
President
Mr. Manel Rosell
CAIXA D’ESTALvIS DE MANRESA
secretary
Mr. Josep Alabern
COL·LEgI OF.D’ENgINYERS INDuSTRIALS
Members
· Mr. Alain Jordà
CITY COuNCIL OF MANRESA
· Mr. Enric Perramon
AuSA CENTER, S.L.
· Mr. Pere Casals
CAMbRA DE COMERÇ I INDÚSTRIA DE MANRESA
· Mr. Xavier Ferras
ACC1Ó
· Mr. Pablo de Lastres
IbERPOTA Sh, S.A.
· Mr. Jaume Claramunt
MAPRO SISTEMAS DE ENSAYO
· Mr. Francesc X. Gil
UNIVERSITAT POLITÈCNICA DE CATALUNYA
011

12. Who are we?
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
corporate advisor council
President
Mr. Manel Rosell
CAIXA D’ESTALvIS DE MANRESA
AMPhOS 21
AuTOMOvILES uTILITARI OS (AuSA)
AuTOTECh ENgINEERINg
bODEgAS ROQuETA
CENTRE CORPORATI u INI6
CONSTRuCCIONES SOMIC
CONSTRuCCIONS COTS I CLARET
CONSTRuCCIONS SALIDO
DENSO bARCELONA
EDICIONS INTERCOMARCALS
FuNDACIÓ PER L’ECONOMIA I EL MÀRQuETINg
FuNDERIA CONDALS
hAYE S LEMMERZ MANRESA
INDÚSTRIAS PONSA
L. OLIvA TORRAS
LEAR AuTOMOTIvE
MÚTuA INTERCOMARCAL
PILAgEST
PujOL MuNTALÀ
RECICLATgE , TRACTAMENT, DIPÒSIT S.L.
SkIS ROSSIgNOL DE ESPAÑA
SuMMA
vILARDELL PuRTÍ
012

13. Who are we?
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
scientific committee
Most Excellent Mr. Antoni Giró Roca
UNIVERSITAT POLITÈCNICA DE CATALUNYA
Dr. Ferran Laguarta Bertran
CENTRE DE DESENvOLuPAMENT DE SENSORS,
INSTRuMENTACIÓ I SISTEMES - CD6
Mrs. Elena Guijarro
CENTRO PARA EL DESARROLLO
TECNOLÓgICO INDuSTRIAL - CDTI
Dr. Rafael Colás
UNIVERSIDAD AUTÓNOMA DE NUEVA LEÓN
Dr. Yvan Houbaert
uNIvERSITEIT gENT -
DEPARTMENT MATERIALS SCIENCE AND ENgINEERINg
013

14. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
Professional
Team
014

15. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
PROFESSIONAL
T
TEAm
he working teams of the Fundació CTM Centre
Tecnològic consist of researchers and technicians
with practical experience in industrial cases; they
are committed professionals who guarantee
total confidentiality in the works carried out.
In addition, this team of scientists and technicians has an
important presence in national and international congresses
and publications which guarantees a direct access to the
knowledge on the latest tendencies and results in our
fields of work.
staff
The team is made up of both, our own staff and uPC staff;
this is so because the Fundació CTM Centre Tecnològic is a
company connected to uPC of the type 1. because of this link,
the research doctors of the Fundació CTM Centre Tecnològic
are considered as researchers linked to the university and in the
same way, the staff of uPC which carries out its researching work
in a permanent manner in the Fundació CTM Centre Tecnològic
are considered staff linked to the centre.
015

16. Professional Team
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
In the year 2010, the staff
consisted of a total of 127
professionals with the
following profiles:
50
evoluTTIoN
4
46
40 UPC
FUNDACIÓ CTM
30
20
10
20 21
Historical evolution
of the staff
9
10 12 The following graphic
5 shows the evolution of the
staff of the Fundació CTM
Centre Tecnològic from the
beginnings. The increase in
the number of graduated
staff or staff with PhD´s has
been constant what has
allowed the increase of the
research potential of the
centre.
016

17. Professional Team
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
140
uPC
120
108 19
FuNDACIÓ CTM
100
93 18
77 19
80
59 24
60
46 25
39 26
40
21 25
19 23
20 26
20 22
17 20
20
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
The Fundació CTM Centre Tecnològic bets resolutely on the
generation of knowledge which is after transferred to companies.
because of this, the increase in the number of qualifications
attached to our foundation is constant.
140
127
120 SChOLARS
111
TEChNICIANS
100 gRADuATED STAFF (3 YEARS) 96
gRADuATED STAFF (5 YEARS)
DOCTORS 83
80 71
65
60
46 42 46
42
40 37
20
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
017

18. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
WHaT does Fundació
cTM centre Tecnològic
do?
018

19. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
WHAT DOES
T
IT DO?
he Fundació CTM Centre Tecnològic works for
companies, organisations and institutions in R+D/IT
projects of their own or together with companies, in
studies and technical support, in analysis and essays,
in the support to innovation and in technical training. Its activity
revolves around six areas of work.
AREA OF MATERIALS TEChNOLOgY
AREA OF FORMINg PROCESSES
AREA OF SIMuLATION AND INNOvATIvE DESIgN
AREA OF ENvIRONMENTAL TEChNOLOgY
AREA OF SuPPORT TO INNOvATION
AREA OF ENERgY
019

20. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
areas
of work
020

21. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
MaTerials TecHnologY
materials
T he Area of Materials Technology (ATM) is the area of
the Fundació CTM which specialises in the research
teCHNOlOGY
into the relation between the microstructures and the
mechanical properties of materials.
ATM is structured into the following
main units of activities:
· ThE MEChANICAL bEhAvIOuR OF MATERIALS
· FORMAbILITY AND MEChANICAL
ChARACTERISATION OF STEELS ShEETS
· SuRFACE ENgINEERINg
· TRIbOLOgY
· TEChNOLOgICAL SERvICES
021

22. Materials
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
The main lines of work of the unit of
Mechanic Behaviour of Materials are:
Materials for tools used in the forming processes of materials (cold
forming, hot stamping of metallic sheets, light alloys injection,
extrusion and forging):
· Mechanical characterisation
· Micro-mechanical design
· Determination of failure micromechanisms
· Effect of the characteristics of the process on the properties of
the component
Fatigue and fracture of structural materials:
· high Strength Steels
· Aluminium alloys
· Castings
· Elastomeres
Determination of internal defects in structural pieces
behaviour in fatigue of structural components
Evaluation of the interaction with the environment: corrosion
resistance, tension corrosion and fatigue corrosion
The main lines of work of the unit
of formability and mechanical
characterisation of steel sheets are:
· Characterisation of mechanical properties of steel sheets
and high strength steels: mechanical resistance, behaviour in
fatigue, impact resistance
022

23. Materials
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
· Formability characterisation of steel sheets and high strength
steels
· Determination of formability curves and evaluation of
deformations in real pieces
The main lines of work of the unit of
surface engineering are:
· Study of technological coatings for functional decor applications
· Study and development of coated systems and/or superficial
modifications for forming tools
· Development of metallic and non metallic coatings over different
substrates by means of PvD technique
· Mechanical and topographic characterisation of surfaces and
coatings
The main lines of work of the unit of
Tribology are:
· Characterisation of the surface damage micromechanism
· Non destructive inspection of the forming tools
· Development of experimental methodologies for the evaluation
of friction and wear in industrial systems with and without
coatings
· Evaluation of the behaviour in fatigue by contact
The main lines of work of the unit of
Technological services are:
· Failure and degradation analysis in metallic and ceramic
components by- Corrosion, Fracture, Wear, Soldering, Chemical
microstructural and mechanical characterisation of the materials
023

24. Materials
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
as an infrastructure for the support
to the development of projects, aTM
counts with a complete laboratory for the
microstructural analysis and mechanical
evaluation of materials:
· uniaxial tests (traction, flexion, compression) with electromechanic
machines of 200 and 250 kN in various environments (saline,
neutral) and at different ranges of temperature (from -40ºC up to
1200 ºC)
· behaviour under cyclic loads: servo-hydraulic machines from
15 and 250kN (with devices for amplifying loads up to 500 kN),
resonance fatigue machine of 150kN (frequency of 250 hz)
· Evaluation of the tenacity for different kinds of materials
· Laboratory hydraulic press of double effect and 150 Tm of capacity
with optical equipment capable of measuring deformations in
test tubes at real time without contact for the determination of
the conformability of steel sheets. It counts with experimental
facilities for the cutting of steel sheet in moulds so as to evaluate
the behaviour of tools and the quality of the cut
· Tribometers for the evaluation of the coefficients of friction and
wear resistance, abrasive and adhesive, up to 900ºC
· Nanoindentator for the evaluation of the mechanical properties
of coatings and of multiphase materials at a nanometric scale
· PvD reactor with pulsed filtered and non filtered cathodic arc
for the preparation of coatings with the possibility of applying
nitruration treatments
· Optical microscopes, a confocal microscope and an electronic
microscope with field emission (FE-SEM) with EDX and EbSD
· Emission spectrometry, LECO C-S
024
· Saline fog camera and kesternic
· Thermographic camera

25. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
ForMing
FORMING
Processes
T
PROCESSES
he Area of Forming processes of the Fundació
CTM is the one specialised in the development and
research into forming industrial processes. The Area
of Processes works on the optimisation of industrial
processes for the forming of materials with the objective of
obtaining materials with improved characteristics.
The main lines of work of the Area of Forming Processes are:
· Study and characterisation of the behaviour of metallic materials
at high temperatures
· Optimisation of the industrial forming processes
· Superficial protection of steels against
oxidation and corrosion
· Development of processing routes for obtaining materials with
nanometric grain size by mechanical milling and severe plastic
deformation by ECAE
· Forming of compound materials
All the above mentioned lines are supported by advanced
scientific equipment for thermomechanical, microstructural and
thermodynamic characterisation.
Next, we offer a brief explanation of each of them.
025

26. Forming Processes
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
study and characterisation of the behaviour
of metallic materials at high temperatures
One of the strong points of the Area of Forming
Processes of the Fundació CTM is in fact, the description
of the characterisation of the behaviour of metallic
materials at high temperatures. It is well known that during
hot deformation materials have to undergo some antagonistic
phenomena such as hardening by deformation or softening
by restoration and/or dynamic recrystallisation. The correct
description and quantification of these phenomena is
still subject of discussion in the scientific community,
in spite of the outstanding developments of the
last decades. From the Fundació CTM, we have
put special emphasis on the prediction of hot flow
curves according to the initial microstructure and
the deformation temperatures and speed, using for
this purpose equations with a physical foundation.
This approach is complemented with the capacity of
predicting even the microstructure resulting from hot
plastic deformation. All of this can be implemented in a
numerical simulation software. The results obtained have
been applied to all kinds of alloys such as carbonated steels,
microalloyed steels, stainless steels, copper, super-alloys and
alloys with a low fusion point (Sn-Pb).
On the other hand, there are industrial processes such as continuous
casting that are carried out under conditions of temperature and
deformation speed that can favour the appearance of fragility
mechanisms and consequently, the superficial cracking of the
026
product.

27. Forming Processes
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
These fragilisation mechanisms depend on the alloy and the
metallurgic phenomena that may occur. In microalloyed steels
for example, the fragilisation can be related with the precipitation
on the limits of the grain, with the transformation of austenite
into ferrite or, because of low deformation speeds and high
temperatures or with diffusion phenomena such as the flow. So
as to be able to carry out a suitable design of the manufacturing
operations that minimise the risk of appearance of cracks one
needs to know the nature of these mechanisms for each alloy.
In general, the study involves the carrying out of traction tests
at high temperatures with the corresponding fractographic and
metallographic evaluation of the samples tested in fracture. The
results developed by the group with regards carbonated steels
are of special interest.
optimisation of the industrial
forming processes
As a result of the knowledge acquired in the characterisation of the
behaviour of materials at hot temperatures and in collaboration
with the Area of Materials Technology and the Area of Simulation
and Innovative Design of the Fundació CTM, it is working on
the simulation and optimisation of numerous industrial forming
problems.
Processes such as:
· Continuous casting processes (handcraft and mould)
· Lamination
· Forging
· Extrusion
027
· Stretching

28. Forming Processes
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
· Cladding
· Stamping
· Spinning and cylindrical and conical lamination
· Forming by electromagnetic pulsation
Most of these processes are developed at high temperatures but
some of them, such as stamping and stretching, are developed
at cold ones. We must highlight the study that the Fundació
CTM is carrying out and which seeks to improve the definition of
the elastic recovery by including the variations presented by the
modulus of Young during the deformation itself.
superficial protection of steels against
oxidation and corrosion
The layer of scale forms continuously during the process of hot
lamination. The layer of rust (secondary) is eliminated just before
the sheet enters the rolling mill. Nevertheless, the time that goes
by between the pickling stage and the first roller is enough for
giving way to the formation of another layer of rust, the tertiary,
which is unavoidable. Its properties, which depend on the chemical
composition of the steel and the conditions of the process, have
a great impact on the final superficial quality of the steel. The
requirements of the customers regarding the properties of the
layer of scale are especially strict with the aim of being able to
guarantee a suitable answer of the material in subsequent steps
of the process such as pickling, stamping or direct coatings.
Studies carried out by qualified staff from the Fundació CTM on
the growth and mechanical behaviour of the scale layer, show
that its properties can be controlled up to the point that its
028
behaviour does not have to be the expected one, that is to say,

29. Forming Processes
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
fragile and abrasive (detrimental for the determination of aspects
such as the lamination rollers) but in suitable conditions, it could
present characteristics such as ductility and great adhesiveness
and evenness to steel; this would bring about many advantages
i.e. reduction of the pickling costs, increase of the productivity,
etc.
given its versatility and low cost, steel is the material most
used worldwide. Therefore, it constitutes a determinant
factor in the development of industry. Its main handicap is
that in the presence of aggressive atmospheres, a high level
of corrosion may appear. It is for this reason that steel has
to be conveniently protected with a proper coating. These
coatings have to present excellent forming properties and
a good adhesion to the steel substrate. The processes of
transformation such as galvanizing make it possible to offer
global, agile and versatile solutions which are adapted to the
global and changing environment in which we find ourselves.
The Fundació CTM accumulates an extensive experience in the
study and characterization of the processes of galvanization
as well as in the proper identification and microstructural
characterisation of the coatings.
obtaining materials with nanometric grain
size by mechanical milling and severe
plastic deformation
The Area of Forming Processes has been developing several
techniques for obtaining nanostructured materials so as to
be able to obtain them massively. During the past 15 years,
029

30. Forming Processes
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
the process for obtaining nanostructured materials (or
with nanometric grain size) has captured the attention of
researchers, this is so, because these structures modify not only
the mechanical and physical properties (electric, magnetic,
hardness, elastic limit) but also the chemical ones (reactivity). At
present, there are two approaches so as to obtain nanometric
materials: the techniques “bottom-up”and “top-down”. The
first group of techniques present problems of massivity of the
manufactured pieces and a difficult control of the porosity and
internal oxidation. The “top-down” techniques are the ones
that have more possibilities of having an industrial scalable
potential; the ones with which, more massive materials can be
obtained. The approach that is being used consists basically in
starting from the microstructured material and then, through
several methods (mechanical milling and ECAE) carrying out
the microstructural tuning with the consequent increase in
the mechanical properties.
Forming of compound materials
This area of the Fundació CTM that has been created recently is
structured within the Area of processes and focuses its activities
on the following issues:
· Forming of fibbers pre-impregnated with resins
· Microtopographical inspection (confocal) of plastics
strengthened with fibbers
· Mechanical characterisation of compound materials
· Implementation of laser ultrasound techniques for the
detection of defects
030

31. Forming Processes
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
laboratory units specifically orientated to
the area of Forming Processes
dilatometer dil 805 BÄhr thErMoanalYs
unit for the study of phase transformations (TTC and CCT curves)
suffered by materials during the heating and cooling cycles
(with and without deformation); flow curves at constant
temperature and speed, both in traction and compression;
tests of relaxation of tensions or interrupted tests. All of these
tests are essential for the knowledge of their behaviour during
the forming processes.
Advanced microstructural characterisation by EbSD
(Electron back Scattering Diffraction) FE-SEM
and TEM techniques; including second phase
particles, mi c ro t e x t u re s , cr yst a llography,
dislocation density, recrystallisation
degree,...
031

32. Forming Processes
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
Microtopographical inspection (confocal)
The Fundació CTM counts with a confocal microscopy unit
(Sensofar PLµ2300) for the inspection of sheets of up to 300mm x
300mm of plastics strengthened with Carbone fibre (Carbon Fibre
Reinforced Polymer CFRP) or glass (graphite Fibre Reinforced
Polymer). The confocal microscopy can detect defects near to
the surface, even if it is the apparently flat surface what was in
contact with the cured mould.
laser ultrasounds
The Fundació CTM together with CD6 carries out research work
on the application of laser-generated ultrasounds. The Fundació
CTM transfers this technology to companies which specialise
in ultrasound inspection and collaborates in the simulation of
the propagation of the transverse and longitudinal acoustic
waves which generates the incident laser. The inspection with
laser-generated ultrasounds (Lu) is a technique which has the
applications of a conventional ultrasound unit but that works
without having contact with the inspected piece; this is so
because it has two lasers, one for the generation of acoustic
waves and the other, for the detection of superficial vibrations
through interferometry. The direction of the propagation of
these transverse and longitudinal waves is important for the
determination of the physical properties of the material such as
the elastic modulus, and it is necessary to resort to simulation by
finite elements so as to know where to position the other laser of
the interferometry unit.
032

33. F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
siMulaTion and
SIMULATION
innoVaTiVe design
T
AND INNOVATIVE
he Area of Simulation and Innovative Design is
the area of the Fundació CTM that specialises in
numerical simulation, both in engineering and in
research and it has the following missions:
· give service to all the projects of companies that may need
DESIGN
numerical simulation in different fields of engineering
· To design and develop tools and small machinery and to
collaborate in the design of productive and experimental
systems
Simulation is a tool in constant development that makes it
possible to efficiently analyse different physical phenomena.
It has contributed significantly to the improvement of design
in engineering and of the methodology of the design cycle
of different industrial applications. It constitutes an essential
technique in the development of new processes, mechanisms
and phenomena in the field of materials and furthermore, it
allows generating products with a high added value.
033

34. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
PROJECTES
INTERNAL
PROjECTS
INTERNS
DISSENY
INNOvATIvE
DESIgN
INNOVADOR
PROJECTES
EXTERNAL
PROjECTS
EXTERNS
SERVEIS
SERvICES
At present, the main activities of the Area of Simulation and
Innovative Design can be classified as shown in the following
diagram:
Simulation and Innovative Design works with commercial
calculation programs by the finite elements method such as
AbAQuS ANSYS and PROCAST; it counts with experience in
simulation of mechanical and thermomechanical behaviour,
static and dynamic calculations, heat transfer, stationary and
transitory calculations, fluid dynamics, electromagnetism and
multi-physical calculations (coupled fields).
For the group, simulation has a double interest: to analyse
systems and processes as well as, to achieve a deeper
knowledge of the behaviour of materials.
034

35. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
The main activities of the Area of Simulation and Innovative
Design are:
· COLD FORMINg
· hOT FORMINg
· ELECTROMAgNETIC FORMINg
· CASTINgS
· vIbRATIONS
· ELASTOMERS
· FLuIDS. OPTIMISATION OF COOLINg SYSTEMS
· INNOvATIvE DESIgN
· uLTRASOuNDS
035

36. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
cold Forming
The main lines of work within the unit of cold forming are the
following:
Estimate of the elastic recuperation:
The objectives in this field focus on the proposal of a
methodology for the correct estimation of the elastic recovery
(springback) as well as, on the compensation of the forming
tools, so as to obtain pieces within the tolerances in the
forming of sheets with high strength steels by studying the
parameters which influence the process. For this reason,
numerical simulation by finite elements is the tool most used,
since it´s proven by a rigorous experimental validation.
It has been proven that, so as to achieve a correct prediction
of the elastic recovery, it is essential to have the knowledge
of the variation of the modulus of elasticity depending on
the plastic deformation and the cyclic behaviour of the AhSS
under study.
A method for the compensation of springback using Abaqus
has been designed. This method makes it possible to obtain
the geometry of the compensated tools (punch, mould and
pusher) in such a way that the piece obtained after the elastic
recovery coincides with the geometry originally designed.
Progressive forming
The progressive forming processes are a set of forming
techniques in which the preform is deformed locally until
obtaining the final shape. This kind of process has the
036
important advantage of reducing considerably the strength

37. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
and size of the machinery needed so as to obtain certain final
geometries.
An important family of progressive forming processes is the
one known as spinning. This family includes the traditional
spinning and the conical and cylindrical laminations.
In the first two processes, a circular preform of sheet goes
around at great speed and is deformed by applying pressure
with a tamper on an also revolving mould. With one or
various passes, the preform achieves the desired shape. In
the cylindrical lamination, a tube of a certain thickness spins
around at great speed while a certain number of tampers,
generally three, reduce locally its thickness. At the end of the
process we obtain a tube with its thickness evenly reduced.
The fine-tuning of the parameters of the spinning processes
is still to this day, a matter of experience, trial and error.
Computer simulation makes it possible to obtain not only
a deeper knowledge of the process (because we have a
complete image of the state of tensions and deformations of
the material) but also, a tool for predicting the effect of the
change of parameters of the process.
Recently, the group has worked on the simulation of the
cylindrical lamination process of steels with a high elastic limit.
This work has included the characterisation of the materials for
this kind of processes and the development of experimental
techniques for validating the simulations.
Prediction of the breaking
At the same time that the development of new high strength
037
steels grants many advantages, it also generates new

38. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
inconvenients during their forming process. The complexity of
the present geometries of work induces nonlinear deformation
paths in multiple-step operations. The simulation methods
used up to this moment for the prediction of possible
fractures of the material during its forming process are way
too conservative. The FLD (Failure Limit Diagram) criteria are
a clear example.
There are several criteria for the prediction of the fracture of
sheets that have been, up till now, in phase of being validated
and also an agreement by the scientific community. Among
these stands out the Forming Limit Stress Diagram (FLSD).
This method has been used by the Fundació CTM obtaining
very good results.
The simulation by finite elements makes it possible to introduce
the FLSD criterion for determining if the piece that has to be
inlaid will present restriction or not. Finally, all this procedure
makes it possible to greatly reduce the experimental tests,
which in many occasions are difficult to carry out and mean
a great initial cost (forming tools). The following figure shows
the same piece experimentally inlaid and simulated by finite
elements (FLSD criterion).
wear
The evolution of the materials being used in the steel forming
industry has put die stamping tools under high mechanical
requirements, which result in an important wear of these and
in many cases in fractures that render them useless. Faced
with these problems, the group of simulation and innovative
design has worked on the development of simulation strategies
038
capable of modelling the wear and failure of forming tools.

39. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
These techniques consist in programming a script for post-
processing the simulation results and in the modelling of tools
with deformable elements.
At present, the group has the capacity for carrying out the
design of tools presenting calculations of the life span that
make it possible to make a correct selection of the material
and adjust the maintenance plans of the productive systems.
Hot Forming
The forming of sheets at high temperatures has gained prominence
in recent years, especially in the car industry. It makes it possible
to obtain pieces with high mechanical properties in relation to
the weight and to reduce negative phenomena related to the
cold forming process, such as springback.
Numerical simulation using finite elements in this field is an
essential tool for the adjustment of this kind of process, as well
as for other processes such as forging, extrusion, lamination, etc.
Numerical simulation using finite elements allows us to study,
among others, the following aspects of the hot forming process:
thermomechanical study of the tools:
· Distribution of temperatures and tensions in the tools during
the forming cycles
· Design and analysis of the cooling systems
· Selection of materials
· Stabilisation cycles of the process
thermomechanical study of the piece:
· Study about the conformability and selection of the
suitable format
039

40. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
· Prediction of the distribution of temperature and final
mechanical strength
research into new hot forming processes
electromagnetic forming
The electromagnetic forming technique is based on the
generation of high intensity transitory magnetic fields
through a rapid discharge (20-150µs) of electric energy on a
specially designed coil. The transitory magnetic field induces
eddy currents on the piece (good electrical conductor); the
interaction between the coil currents and the ones induced
on the piece, generate forces of repulsion that accelerate the
piece and make it deform. This forming technique presents
important advantages regarding conventional techniques;
some of these advantages are: reduction of the elastic recovery
and the speed of the process.
The nature of the process in which electromagnetic, mechanical
and thermal phenomena in transitory regime are developed,
involves the need of using calculation tools by the finite
elements method in the design stages of the process.
Simulation makes it possible to evaluate the electromagnetic
efficiency of the coil, obtaining the evolution of the
electromagnetic fields and forces developed during the electrical
discharge. This analysis, solved together with the thermal
and mechanical analysis, makes it possible to determine the
temporary evolution of the distribution of strains, temperatures
and deformations of both the piece and the coil.
The results obtained in the simulation together with the proper
selection of materials, have allowed us to obtain a robust and
040

41. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
suitable design of the forming tools and the final deformation
and shape of the piece.
casting
In the last few years simulation has joined the workflow of the
foundry companies helping to optimise the components and
manufacturing processes while reducing the time and costs
that characterise the test and error method.
The Simulation department counts with a set of programs
which make it possible to simulate a wide range of casting
processes such as:
· Casting by gravity
· high Pressure Die Casting (hPDC) or Low Pressure Die
Casting (LPDC)
· Continuous casting
With these tools the department can carry out a complete
analysis of the casting process that includes:
· Cast steel flow in the cavity until is full
· Profile of temperatures and stresses on the pieces and the
moulds during the process
· Evolution of the solidification front
· Detection of the appearance of different kinds of defects
· Determination of the microstructure of the component
All these data make it possible to approach the design or
improvement of a casting process without having to actually
manufacture pieces until very advanced stages of the process.
At the same time, the reasons for the appearance of defects
in an already established industrial process can be detected
quickly facilitating (this way) the correction and improvement.
041

42. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
The tests carried out at the experimental facilities of Fundació CTM
allow us to validate the predictions made by the simulations.
Vibrations
One can consider a vibration the temporary periodical
variations of different magnitudes. In fact, a mechanical
vibration is the movement of a body that oscillates around
a point of equilibrium.
The causes of mechanical vibrations are many but basically, they
are closely related to mechanisation tolerances, calibration,
relative movements between touching surfaces or the balance
of rotating or oscillating parts.
The phenomena we have just listed almost always produce a
movement of the system from its point of stable equilibrium
originating a mechanical vibration. The majority of the
vibrations in machinery and structures are undesirable
because they increase the strains and for the loss in energy
that accompanies them. Furthermore, they are the source of
the wearing down of materials, damage due to fatigue as well
as of annoying movements and noises.
Simulation by finite elements makes it possible to obtain
the intrinsic modes of a structure, i.e. the intrinsic resonance
frequencies of the structure with the representation of the
deformation of the said frequencies (MODAL MODEL). The
knowledge of the intrinsic modes of the structure enables the
evaluation of its usage independently of its area of operation.
Furthermore, the results of the modal analysis facilitate the
definition of structural improvements on contributing a numeric
and graphic model of mechanical behaviour.
042

43. simulation/design
F u n d a c i ó c T M
c e n T r e T e c n o l ò g i c
For the determination of the dynamic behaviour of a mechanical
structure, 3 different models exist:
· Spatial model: All structures can be modelled spatially by
means of a set of mass systems, a shock absorber and an
equivalent mould. For this purpose, we define a series of
characteristic matrices of the system (matrix of the mass,
matrix of the shock absorber, matrix of stiffness) that is under
analysis
· Modal model: given the said matrices, the modal analysis is
limited to the resolution of a problem of autovalues
· Response model: Mathematical expression which, based on
the modal model and the shock absorbency value, enables
us to obtain the FRFs of a structure, i.e. what its behaviour is
in relation to the excitation frequency
Fatigue of the components
The application of loads or periodic movements on a
component can lead it to fail at load levels that are much
lower than it would be expected in a monotonic load situation.
Predicting life under fatigue of a component can be dealt with
using two very different strategies:
· To reproduce the working conditions in the laboratory and
cycle until the part fails
· To study the properties of the material under fatigue and
estimate its life according to the loads it has to bear
In the study of behaviour under fatigue simulation is a very
effective tool given that it enables the determination of the states
of tensions and deformations of the components in service under
very different load states. These tensions and deformations can
043