Process Simulation

Process modelling and simulation is the cornerstone of Digitalization and Industry 4.0. In this competence field the focus lies on the development of simulation methods, CAE-workflows and material models for the systematic optimization of all manufacturing processes used to create fiber reinforced polymer composite parts.

Application-specific implementation of simulation tools based on commercial and/or open source CAE software are used to carry out systematic studies for optimizing process parameters, tools, component design, sensor positioning and semi-finished product selection. Furthermore, software tools are developed for data transfer within consistent simulation chains, e.g. transfer of process simulation results into mechanical component simulations. Finally, the validation of individual material models based on self-developed experimental and numerical methods for material characterization are also considered.

The research content is oriented towards the key composites manufacturing technologies of thermoforming, compression molding, liquid composite molding (LCM) and induction welding, which complement the experimental activities of the program area manufacturing science.

Process Simulation at IVWClick to load external video!
More information in our privacy policy

Dr.

Miro Duhovic

Manager Process Simulation

Special Expertise: Finite element-based multiphysics simulation of complex composite manufacturing processes, material and process characterization, composite model development

Telephone: +49 631 2017 363

miro.duhovic@leibniz-ivw.de

Vita

Special Expertise

Latest commercial and open source software packages
Automatable scripts (e.g. Python) for data transfer and parameter studies
Modular shell and beam element material model for accurate prediction of fiber orientation, e.g. in organic sheets and customized preforms
User-defined material model for C-SMC materials ("compaction" and "flow")
One-stop-shop: material characterization, input and validation data can all be generated in-house
Highly skilled team with many years of simulation experience

Economic Sectors	Applications (Examples)
Mobility	SMC compression molding simulation for automotive body panels and thermoforming simulation of aircraft stringer profiles
Sports & Recreation	Draping simulation for helmets
Energy	Infusion simulation for rotor blades

Materials and Questions

Typical Materials

GFRP, CFRP
Thermosets and Thermoplastics
Continuous and discontinuous fiber reinforced systems

Current research topics

Faster process simulations through model order reduction and machine learning
Thermoforming simulation for customized preforms made from unidirectional reinforced materials
Simulation of thermoforming processes with tapes based on recycled carbon fibers
Simulation/analysis of fluid-structure interactions (hydrodynamic compaction)
Material models for C-SMC with very high fiber volume fraction

Typical Questions

How do different semi-finished products behave during the pressing process?
How can fiber orientations and wrinkling be predicted during thermoforming of organic sheets?
How can the filling time in LCM processes be optimized by adapting gating scenarios?
How can online control be implemented in continuous induction welding?

Projects in this field

DamageDict

Simulative Damage Prediction of Scrim Laminates

The aim of the DamageDict project is to develop a simulation

software tool that accurately predicts the failure

of composite materials with little experimental effort.

InjectProfile

Thermoplastische Low-Cost Flugzeug-Profile

Material Model for the Compression Behavior in SMC

Development of an efficient and accurate material model for the prediction of the flow behavior and the fiber orientation in SMC materials

Prozessdigitalisierung

Prozessdigitalisierung von Carbonfaser Sheet Molding Compounds

Hauptziel ist die Steigerung der Geschwindigkeit des kontinuierlichen Induktionsschweißprozesses von kontinuierlich kohlenstofffaserverstärkten Thermoplasten, speziell von Organoblechen, in Verbindung mit einer resultierenden Fügequalität auf Autoklavniveau.

SOPHIA

Smart Processes and Optimized Designs for High Production Cadences

Development of a new integral foam construction with thermoplastic cover layer for cabin components using the sidewall as an example

Thermoforming Simulation of Organosheet Materials

Forming behavior of continuous fiber reinforced thermoplastics

Forming behavior of continuous fiber reinforced thermoplastics in the thermoforming process and to make statements about resulting fiber orientation, final contour, and wrinkling

ThermoStrut

Novel Thermoplastic Aerospace Struts

Life time enhancement of thermoplastic FRP-metal-hybrids by reducing process induced residual stresses

ZEUS

Integral Thermoplastic Design Concepts and Processes

Active hybrid structures enable a novel situation-dependent adaptation of aircraft aerodynamics, which increases efficiency and reduces noise pollution.

Publications from the IVW papers in this field of competence

Weber, T.(2018)
Herstellprozesssimulation zur Vorhersage der Faltenbildung in der Prepreg-Autoklav-Fertigung
- Download Abstract
Schöpfer, J.(2011)
Spritzgussbauteile aus kurzfaserverstärkten Kunstsoffen: Methoden der Charakterisierung und Modellierung zur nichtlinearen Simulation von statischen und crashrelevanten Lastfällen
- Download Abstract
Louis M.(2004)
Zur Simulation der Prozesskette von Harzinjektionsverfahren
- Download Abstract
Huber, U.(2001)
Zur methodischen Anwendung der Simulation der Harzinjektionsverfahren
- Download Abstract

External Publications "Process Simulation"

An experimental characterization of wrinkling generated during prepreg autoclave manufacturing using caul plate

https://journals.sagepub.com/doi/10.1177/0021998319846556

Advanced process simulation of compression molded carbon fiber sheet molding compound (C-SMC) parts in automotive series applications

https://doi.org/10.1016/j.compositesa.2022.106924

Transverse liquid composite moulding processes for advanced composites material manufacturing

https://doi.org/10.1080/14658011.2022.2108983

Material Characterization and Compression Molding Simulation of CF-SMC Materials in a Press Rheometry Test

https://www.scientific.net/KEM.809.467

Polarization imaging for surface fiber orientation measurements of carbon
fiber sheet molding compounds

https://doi.org/10.1016/j.coco.2022.101456

A combined experimental–numerical approach for permeability characterization of engineering textiles

https://onlinelibrary.wiley.com/doi/10.1002/pc.26064

Machine learning for polymer composites process simulation – a review

https://doi.org/10.1016/j.compositesb.2022.110208

Influence of polymer matrix on the induction heating behavior of CFRPC laminates

https://www.sciencedirect.com/science/article/pii/S1359836821009276?via%253D

Computational modelling and analysis of transverse liquid composite moulding processes

https://doi.org/10.1016/j.compositesa.2023.107433

← Press & Joining Technologies

↰ Competence Fields

Roving & Tape Processing →