Process Simulation

Today, process simulation plays a crucial role in composite manufacturing science. It helps us understand,refine and optimize the processes we use to make composite parts.

At IVW, process simulation is focused on five key topics: processing of thermoplastic sheet materials, liquid composite molding, welding of thermoplastic composites by induction, winding and tape laying of unidirectional reinforced composites and the processing of bulk molding and structural molding compound materials. Process simulation begins with material characterization, a procedure of defining and measuring the material’s behavior, usually deformation or flow as well as thermal behavior, experienced under the specific conditions during manufacturing. In most cases temperature, pressure and time are the key parameters. The experiments provide the source of input and form of verification required for computer simulations which can then be performed in place of physical experiments using mathematical and engineering software, essentially allowing what engineering software providers have termed “virtual manufacturing”.


Miro Duhovic

Manager Process Simulation

Special expertise:
Finite element based multi-physics simulation of complex composites manufacturing processes, material and process characterization, composite material model development
Room: 58/268
Economic Sectors Applications (Examples)
Aeronautics Wing flaps
Automotive Chassis and body panels
Engineering Hybrid support structures
Sports & Recreation Bicycle seats
Military & Security Various
Energy Rotor blades

Special Expertise

  • Characterization and finite-element based multi-physics simulation of highly complex composites manufacturing processes

Typical Materials

  • GFRP
  • CFRP
  • Continuously reinforced systems

Materials and Questions

Typical Questions

  • Which characterization experiments are necessary for performing thermoforming simulation of tailored blanks?
  • How does the insertion position and blank size affect the flow front development and the formation of weld lines in compression molding processes?
  • Which characterization experiments are necessary to determine the permeability of a textile in all three spatial directions and how is an RTM filling simulation set up correctly so that the orientation of the textile in the part is correctly represented?

Projects in this field

Publications from the IVW papers in this field of competence

  • Weber, T.

    Herstellprozesssimulation zur Vorhersage der Faltenbildung in der Prepreg-Autoklav-Fertigung

  • Schöpfer, J.

    Spritzgussbauteile aus kurzfaserverstärkten Kunstsoffen: Methoden der Charakterisierung und Modellierung zur nichtlinearen Simulation von statischen und crashrelevanten Lastfällen

  • Louis M.

    Zur Simulation der Prozesskette von Harzinjektionsverfahren

  • Huber, U.

    Zur methodischen Anwendung der Simulation der Harzinjektionsverfahren